UNIT 6

Hydraulic and Pneumatic Circuits

 Hydraulic & Pneumatic Symbols

PTO
 OR

Meter in circuit :

Working :

When spool valve is operated pump is connected to blind end of cylinder thus piston moves
forward causing work done. During return stroke the fluid returns back through non return valve.
Meter in circuit are generally used when load characteristics are constant and positive, in
grinding and milling machine.

Figure shows circuit connections of a meter in circuit in which the flow control valve is placed in
the primary line, directly after load. In meter in circuit speed control is achieved by changing the
flow adjustment of flow control valve which controls the oil going to the blind end of the
cylinder.

Applications : Meter in circuits are used in - Surface Grinder, Milling machine.

 OR

a) identify the following circuits in figure No 1

b) Make correction if any (Redraw)
c) Label it and explain its working
d) State its applications

a) The given figure is Meter in circuit.

Corrected fig as below

Working of Meter in Circuit :

Figure shows circuit connections of a meter in circuit in which the flow control valve is placed
in the primary line, directly after load. In meter in circuit speed control is achieved by changing
the flow adjustment of flow control valve which controls the oil going to the head end of the
cylinder. Meter in circuit are generally used when load characteristics are constant and positive.
 OR

Meter out circuit :

By pass (or) Bleed off speed controlling hydraulic circuit :

Working :

Bleed off circuit does not control the flow going to actuator or flow returning from the actuator.
It controls diverted part of the fluid to control the flow. In this circuit Flow control valve are
placed in the bypass line. In this circuit neither incoming nor outgoing flow is metered. In this
method pressurized fluid coming out of pump is diverted and bypassed to oil reservoir. This
circuit is used for controlling linear speed of piston in double acting cylinder. Here speed of
piston is depends on difference between pump delivery flow and flow being by passed to tank
through flow control valve.

Applications :

1. broaching machine
2. shaping machine
3. planing machine
4. hydraulic motor brake circuit 5. Concrete mixer on truck.
 OR

i) Identify the following circuit in figure No. 1

ii) label and explain its working
iii) state its applications

i) The figure shows a bleed off circuit.

ii) Working :

Bleed off circuit does not control the flow going to the actuator or flow returning
from the actuator It controls diverted parts of fluid to control the flow in this circuit
adjustable throttle is placed bay pass line. Bleed of circuit is also used for controlling
the linear speed in double acting cylinder in this circuit neither incoming nor
outgoing flow is metered in this method pressurized flow it coming out of pump is
diverted and by passed to oil reservoir the speed of piston is depends on difference
between pump delivery flow and flow being by pass to reservoir through throttle
valve.

iii) Applications :
1) Use in hydraulic shaping machine, planer machine.
2) Used for control of broach in broaching machine.
3) It is suitable in constant pressure.
Used where precise speed control is not require.
Applications of hydraulic circuits :
Hydraulic circuit for Milling machine :
 6.1 Simple Pneumatic Circuits.
Draw general layout of pneumatic circuit and label all the parts. 4m
Explain with sketch and label pneumatic circuit for speed control of a double acting cylinder.
6m

Speed control circuit is used to control the speed of pneumatic actuator; this is achieved by
controlling air supplied to the actuators. The air flow to actuator is controlled either the supply
line or drain line.

In speed control of a cylinder, a flow control valve along with a check valve is normally used,
but this combination provides speed control in one direction. In case of speed control in both
direction of double acting cylinder, two sets of combination flow control and check valve are
used. Speed in a extension and retraction can be changed independently. It should be noted that
position of check valves permits free flow of air to the cylinder chambers and throttled flow of
air from the chamber.
Pneumatic Sequencing Circuits :

Generally in mass type production industries when two (or) more than two operations / activities
are done sequentially then sequencing circuit is used. For getting output we use double acting
actuators in a predetermined sequence.
Sequencing is done by two methods namely pressure dependents and position dependent. In
position based sequencing the cams attached to the actuators (cylinders) operate the valves
censing another actuator to move. This method is commonly used in pneumatics. A simple
position dependant sequencing of two double acting cylinders in shown in fig when start button
is pushed by the operator the cylinder one is extended when it reaches the desired position a 2/2
D.C. valve is actuated which provides impulse to the 4/2 D.C. valve of second cylinder causing it
also to extend. Thus the position based sequencing is achieved.
Pressure dependent Pneumatic Sequencing circuit :

Construct the pneumatic circuit using sequence valve to control two applications performed in a
proper sequence and describe it’s working. 8m

Pressure dependent sequencing circuit :

The circuit is used for drilling a hole in work piece.

The sequence operation is

a) Clamping of work piece

b) Drilling
c) Decamping and drill taken out from hole.
 The DC valve takes centre position (no 3.) no compressed air supplied to either of cylinder C1
or C2. Now undrilled work piece is kept on fixture seat. The compressed air from compressor is
going to vent via DC valve so no movement of cylinder C1 or C2.
Now compressed air start supplying directly to C2 and through sequence valve to C 1 When
compressed oil enters through port A2 of cylinder C2 piston will advance and immediately
clamps the work piece.
At the same time compressed air flow towards port A1 of cylinder C1 but through
the sequence valve.
Some higher pressure is set at pressure relief valve of sequence valve when the pressure of
flowing air reaches this set value the sequence valve opens and air enters through port A1 into
cylinder C1 due to this piston advances comes down so that drilling starts.
When operator again operate foot lever of DC valve it takes position 2 and both piston retracts
and work piece de-clamps and drill comes out of drilled hole.
Application of Compressed Air in Braking System :
 Fig shows complete layout of Air Brake System. It consists of Air filter, unloading valve, Air
compressor, Air reservoir, Brake valve and 4 numbers brake chamber.

Working : The compressor takes atmospheric air through air filter, and compresses the
air. This air is stored under pressure in air reservoir. From this reservoir air goes to various
accessories of vechile which operates on compressed air. Part of air goes to brake valve.
The control of brake valve is done by driver who controls the intensity of braking
according to emergency.

What are applications of pneumatic circuit? Draw a circuit of any one. 6m

(02 marks for application, 03 for figure, 01 for label)

applications of pneumatic circuit :

1. Air suspension system.

2. Air braking system
3. Boring machine
4. Pneumatic drill
5. Pneumatic gun
6. Pneumatic wood cutter
7. Pneumatic hammer
8. Pneumatic chain saw

Note: credit to suitable diagram of any one appropriate application of pneumatics circuit.
OR
Give the application of hydraulics and pneumatics in automobiles. Explain any one of them with
neat sketch. 8m

(applications- 2 Marks, Sketch- 3 Marks, Suitable explanation- 3 Marks)

Application of hydraulics and pneumatics in automobiles

1. Hydraulic braking system.

2. Hydraulic power steering system
3. Air suspension system.
4. Air braking system.

Note: credit to suitable explanation of any one appropriate application of hydraulics and
pneumatics in automobiles.

2. Hydraulic power steering : Rotary valve type power steering

This is used to reduce the turning effort required to steer the wheels. It consist of
hydraulic pump, gear box, rotary spool type D.C. valve and hoses. The steering wheel is
connected to the one end of rotary spool valve while at other end of valve worm is
connected. The worm rotates the nut making the sector to turn which turns the road wheels
at angle.
When driver turns the steering wheel, the spool valve turns directing the
pressurized oil from pump to appropriate side of the nut applying the effort on that side.
This helps in reducing the effort of driver.
 OR

Explain hydraulic power steering with neat labeled sketch. (Optional)

Rotary valve type power steering

This is used to reduce the turning effort required to steer the wheels. It consist of hydraulic
pump, gear box, rotary spool type D.C. valve and hoses. The steering wheel is connected to the
one end of rotary spool valve while at other end of valve worm is connected. The worm rotates
the nut making the sector to turn which turns the road wheels at angle.

When driver turns the steering wheel, the spool valve turns directing the pressurised oil from
pump to appropriate side of the nut applying the effort on that side. This helps in reducing the
effort of driver.

OR

Reaction piston type hydraulic steering system (Optional)

It consist of piston connected to chassis, a moving cylinder, ball joint connected to drop arm
and sliding spool valve The spool valve is operated by ball joint. When the steering wheel is
moved to right, the ball joint connected to the drop arm moves the spool valve to right against
spring pressure. This allows hydraulic pressure to pass to the rear of the piston. As piston is
stationary the pressurized fluid reacts against the piston and pushes the cylinder to the right. The
fluid from front of piston is returned to the reservoir. Thus it helps in reducing the effort applied
by Driver.
3. Air suspension system :
 4) Air Braking System :

Fig shows complete layout of Air Brake System. It consists of Air filter, unloading valve, Air
compressor, Air reservoir, Brake valve and 4 numbers brake chamber.

Working: The compressor takes atmospheric air through air filter, and compresses the
air. This air is stored under pressure in air reservoir. From this reservoir air goes to various
accessories of vehicle which operates on compressed air. Part of air goes to brake valve.
The control of brake valve is done by driver who controls the intensity of braking
according to emergency.
Compare hydraulic and pneumatic circuit (any six points) 6m

SR. Hydraulic circuit pneumatic circuit

NO.
01 Used for circuits up to 700 bar Operative below 10 bar pressure.
pressure.
02 Uses hydraulic oil as a medium. Uses air as a medium.
03 Pump is used to pressure the oil. Compressor is used to pressurize the air.

04 Since hydraulic oil is reused in the circuit Air is taken from atmosphere and is vented to
hydraulic oil tank is a must and there are atmosphere after use. Hence
return lines. no return lines. Air reservoir is used to
store pressurized air.
05 The rigidity of the system using The rigidity of the system using
hydraulic circuit is good. Pneumatic circuit is poor.
06 Moderate operating cost. Operating cost is low.
07 Maintenance is critical. Maintenance is simple.
08 Very suitable for accurate speed/feed No accuracy in movement. Due to
movement of cutting tool mechanism. compressibility of air.
Due to non compressibility of oil.

09 The system using hydraulic circuit is Pneumatic circuits are very clean.
not clean due to oil leakages.
10 Weight to pressure ratio is small. Weight to pressure ratio is high.
11 Problem of cavitations is serious in No problem of cavitations.
hydraulic circuit.
12 Oil is changed as per schedule. No need of change of air as per
schedule.
13 Limited energy is stored in Large amount of energy stored in air tank.
accumulator.
14 Speed is always limited. A very high speed is possible.
15 While working less noise. While working more noise.
16 Oil treatment by oil filter takes place in Air treatment is required so use of FRL unit
power pack. in this system.
17 Leakage problem identify by Leakage problem easily identify by
observation of dirty and sleepry sound/noisy operation.
place.
17 Applications: Hydraulic circuits are used Applications: Pneumatic circuits are used
in tackling heavy loads, hence used in when loads are much lighter. Hence used in
earthmoving equipments, CNC-VMC transferring the light weight components,
machines. Hydraulic braking ,Material vacuum handling in printing press, food
handling.etc. industry. Special
purpose tools, Air braking.etc.
Question Bank
Hydraulic Circuits
1) Draw a symbol for pressure relief valve and variable speed unidirectional pump.4m
2) Draw the symbols for following i) Filter ii) Hydraulic pump iii) Double acting cylinder iv)
3/2 DC valve. 4m
3) Explain meter in type hydraulic circuit. 4m
4) Draw meter-in circuit and explain its working.
5) Draw a neat label sketch of meter-out hydraulic circuit.4m
6) Explain with neat sketch bleed off circuit. 4m
7) Sketch the bleed-off-hydraulic circuit and state any two applications of it.
8) Explain construction and working of hydraulic power steering.

9) Explain hydraulic power steering with neat labeled sketch.

10 Draw layout of hydraulic steering system. Explain its working. 6m

11 Draw the neat labeled layout of hydraulic braking system and explain its working.
8m
12 a) identify the following circuits in figure No 1
b) Make correction if any (Redraw)
c) Label it and explain its working
d) State its applications
 13) i) Identify the following circuit in figure No. 1
ii) label and explain its working
iii) state its applications.

14) Simple Pneumatic Circuits.

15) Draw pneumatic symbols of following i) 4x3 DC valve ii) Tandem cylinder
iii) Variable flow control valve iv) Bi-directional air motor.
16) Sketch and label pneumatic circuit for speed control of a double acting cylinder.6m
17) Explain sequencing pneumatic circuits with neat sketch. 8m
18) Draw general layout of pneumatic circuit and label all the parts. 4m
19) Explain with neat sketch pneumatic speed control circuits.4m
20) What are applications of pneumatic circuit? Draw a circuit of any one. 6m
21) Draw and explain pneumatic circuit to control the speed of double acting cylinder. 6m
22) Construct the pneumatic circuit using sequence valve to control two applications performed
in a proper sequence and describe it’s working. 8m
23) Draw general layout of pneumatic system and label the components. 4m
Combination Questions : (On Hydraulics & Pneumatics System)

24) Compare hydraulic and pneumatic circuit on the basis of - fluid used, ease of
operation, noise, speed, cost, application. 6m
25) Give the application of hydraulics and pneumatics in automobiles. Explain any one of them
with neat sketch. 8m
26) Compare hydraulic and pneumatic circuit ( any six points) 6m