Exercise 7 Door control

Problem description:
A double-acting hydraulic cylinder is used to open and close a furnace door. Inching
operation allows the door to be driven to any desired intermediate position. The cylinder is
hydraulically clamped in all such position.
The above process can be automated using electrohydraulics. The proposed (theoretical)
hydraulics circuit is shown below (Figure 4):

Figure 4: Theoretical hydraulics circuit

Problems encountered by theoretical circuit:

With the above circuit, both Y1 and Y2 has to be actuated to allow the piston to extend. If the
cylinder is to be stopped during its forward stroke at any intermediate position between its
end positons, Y2 is de-actuated. Nevertheless, during the return stroke, the piston could not
be stopped at any intermediate position.

Moreover, pressure built up in the piloted non-return valve when Y1 was pressed and Y2 was
not. This jammed the non-return valve and thus compromised its use. The latter had to be
depressurised using a pressure-relief tool. Therefore we redesigned and implemented another
electrohydraulics circuit to mitigate all the above problems. The electrohydraulics circuit is
shown below:

Figure 5: Implemented electrohydraulics circuit for door control

Components used:

Double acting cylinder

4/3-way valve, spring-centred, solenoid actuated
4/2-way valve, spring return, solenoid actuated
Piloted non-return valve
1-way flow-control valve
Main switch, Pushbuttons PB1 and PB2
Relay switches, K1 and K2

What does a double-acting cylinder cost?

The typical price range of double-acting cylinders used in the practical (Festo)
Do you know the price of the equipment set for Electrohydraulics Basic
Level TP601?
What is the purchase price of a hydraulic excavator?

A typical hydraulic excavator used primarily for ditch cleaning and small excavating
applications costs about $272,000 which is about Rs 9.6millions in terms of local currency.
The annual maintenance fee is about $90,000 which is about Rs316000.

Exercise 9 Feed for drilling machine

Problem description:
The feed of a drilling machine is to be automated. When carrying out drilling with large
diameter drilling bits, it is necessary to achieve constant feed characteristic and a finelyadjustable feed speed. The machine is therefore to be equipped with hydraulic feed, which
must provide a rapid-traverse feed motion and a infinitely-adjustable working feed motion.
The return stroke is to be initiated by pressing a second pushbutton. During this phase, the
flow control valve is to be bypassed by means of a non-return valve.
The above process can be automated using electrohydraulics. The proposed (theoretical)
hydraulics circuit is shown below (Figure 6):

Figure 6: Proposed (theoretical) electrohydraulic circuit

It should be noted that the for the hydraulics circuit, only the components were given and
therefore, the connections had to be done.

There is only one limitation with the proposed circuit (Figure 6), which is the unavailability
of the 2/2-way spring-return, solenoid actuated valve. Therefore, the latter was replaced by a
4/3-way spring centred, solenoid actuated valve and the circuit was properly implemented
and tested on the board.
The redesigned circuit is shown below (Figure 7):

Figure 7: Implemented electrohydraulics circuit for automation of feed for drilling machine

Components used:

Double acting cylinder

Limit switches (roller lever valves) S1 and S2
Pressure gauge
4/3-way valve, spring centred, solenoid actuated
One-way flow control vale
4/2 way valve, spring return, solenoid actuated
Main switch button, pushbuttons S3 and S4
Relay switches K1 and K2

What is the purpose of the Hydraulics 2000 Transparent models?

What do these transparent models illustrate more clearly than the
components mounted on the profile plate?
Have you worked with the Hydraulics electronic transparencies?

Exercise 12 Assembly device

Problem description:
An assembly device is used to press-fit a plastic bush into a steel workpiece. A screw is then
inserted to secure the connection. When the START pushbutton S1 is pressed, the vertical
double-acting A presses the plastic bush into the steel workpiece. When the pressure in the
piston chamber of the press cylinder reached 4.5 MPa (4.5bar), the horizontal hydraulic
motor screws in the left hand threaded coarse-pitch screw. When RETURN pushbutton S2 is
pressed, the press cylinder A retracts and the motor M stops.
Some parameters to be respected:

The cylinder must no slip when the hydraulic power pack is switched off.
Measures must be taken to ensure that the motor cannot rotate clockwise under any

circumstances.
A visual indicator must show the position of the detended RETURN pushbutton S2. The
visual indicator must not go out, allowing a restart, until the switch has been unlocked.

The above operation can be automated using electrohydraulics. Figure 8 below shows the
designed and implemented electrohydraulics circuit.
Components used:

Double acting cylinder

Piloted non-return valve & non-return valve
Pressure gauges
Pressure switch B1
4/3-way valve, spring-centred, solenoid actuated
4/2-way valve, spring return, solenoid actuated
Pressure relief valve
Hydraulic motor, 8L/min
Main switch, pushbutton S1, detented pushbutton S2
Relay switches, K1, K2 and K3
Lamp, L1

Note: The non-return valve was used to prevent clockwise motion of the motor.

Figure 8: Implemented electrohydraulic circuit for assembly device