Industrial Automation: BITS Pilani, Pilani Campus

Industrial Automation
BITS Pilani, Pilani Campus

Automation means
Replacing the human muscle power

What are the muscle in automation
Prime movers: Mechanical attachments
electrical machines or diesel, petrol and steam engines

screw jack, lever, rack and pinions etc
Not only these

Enclosed fluids (liquid and gases)

Hydraulic system: Pascals law
the pressure in an enclosed fluid is uniform in all the

directions

Fluid power: Muscle that
moves industries
Technology that deals with
• Generation
• Control
• Transmission
of power using pressurized fluids
Fluids
Liquid (hydraulic)
Gas (pneumatic)

Fluid Power with Applications

An automation system: What
all you need to implement it

Hydraulic or pneumatic

We might need
Compressor- motor or engine

Accumulator/ storage tank- for constant pressure -Air is
compressible it will take time to generate required
pressure
Control Valve-
Actuators -

Components in hydraulic and
pneumatic system
Tank /reservoir
Pump/compressor
Electric motor
Valve- trying to control 1. direction of flow, 2. rate of flow 3.
pressure
Piping
Actuators

Hydraulic system

Pneumatic system

Hydraulic pump
In general pumps speed is constant and it deliver equal volume

of liquid
Controlled by external elements
We can use servo control motors to change flow rate etc but
system becomes complex
hydraulic pumps are characterized by
Flow rate, power consumption, drive speed pressure delivered,
efficiency
Volumetric efficiency=actual vol/max theoretical vol
Power efficiency= output hydraulic power to the input

mechanical/electrical power

Hydraulic pump types
Centrifugal
Reciprocating

Centrifugal pump
uses rotational kinetic energy to deliver the fluid
the delivery is not constant and varies according to the

outlet pressure
not suitable for high pressure applications
generally used for low-pressure and high-volume flow

applications
20-30 bars Max
specific speed ranges from 500 to 10000

Reciprocating pump
also known as positive displacement pump or piston pump
Small quantity and large pressure
Depending on the area of cylinder the pump delivers

constant volume of fluid in each cycle independent to the
pressure at the output port

Pump lift
In general he pump is placed over the fluid storage tank
pump creates negative

pressure at suction
Pressure head=p g h
Cavitations reduces this max pump lift

Cavitation
The cavitation is the formation of vapor cavities in a liquid

The cavities can be small liquid-free zones ("bubbles" or "voids")
formed due to partial vaporization of fluid (liquid
Rapid change in pressure (at low pressures) causes it

At higher pressure voids implode and generate a shock wave
Can be avoided at lower at lower flow velocities

Thus inlet suction pipe dia is more (1.5x approx)
Pump lift should be minimum to avoid cavitation and increase

pump efficiency

Pressure regulation
the process of reduction of high source pressure to a lower

working pressure suitable for the application
What will happen if V1 is closed

pump might damage/fail due to its own pressure

When pressure regulator valve
is used frequently
• This leads to the substantial loss of power
• This may lead to increase in fluid temperature because
the energy input into fluid leads to the increase in fluid
temperature
• You might need to install heat exchanger in to the
storage tank to extract the excess heat
• Motor power consumption is more in such condition
because the outlet pressure is higher than the working
pressure

Advantages
of Hydraulic system
• The hydraulic system uses incompressible fluid which
results in higher efficiency.
• It delivers consistent power output which is difficult in
pneumatic or mechanical drive systems.
• Hydraulic systems employ high density incompressible
fluid. Possibility of leakage is less in hydraulic system as
compared to that in pneumatic system. The maintenance
cost is less.
• These systems perform well in hot environment
conditions.

Disadvantages
of Hydraulic system
• The material of storage tank, piping, cylinder and piston
can be corroded with the hydraulic fluid. Therefore one
must be careful while selecting materials and hydraulic
fluid.
• The structural weight and size of the system is more
which makes it unsuitable for the smaller instruments.
• The small impurities in the hydraulic fluid can permanently
damage the complete system, therefore one should be
careful and suitable filter must be installed.
• The leakage of hydraulic fluid is also a critical issue and
suitable prevention method and seals must be adopted.
• The hydraulic fluids, if not disposed properly, can be
harmful to the environment.
Classification of Hydraulic Pumps
A. Non-positive displacement pumps
Hydrodynamic pumps-fluid pressure is propotional to
rotor speed- good for low pressure and high volume-
provide smooth and continuous flow- flow output
decreases with system resistance- Thus flow rate
depends upon rotational speed as well as system
resistance

Classification of Hydraulic Pumps
B. Positive displacement pumps
deliver a constant volume of fluid in a cycle - The output
fluid flow is constant and is independent of the system
pressure (load) – high and low pressure liquids area are
separated hence fliuid cannot lead back- high pressure
and volumetric efficiency, high power, change in
efficiency throughout the pressure range is small and
wider operating range pressure and speed
The fluid flow rate of these pumps ranges from 0.1 and
15,000 gpm, the pressure head ranges between 10 and
100,000 psi and specific speed is less than 500

Positive displacement pumps
It is important to note that the positive displacement pumps

do not produce pressure but they only produce fluid flow
Unblocked- partially blocked- fully blocked
When fully blocked pressure increases weakest component

will break- thus safety valves always used
Important positive displacement pumps are gears pumps,

vane pumps and piston pumps

Gear Pumps
• External gear pumps
• Lobe pumps
• Internal gear pumps
• Gerotor pumps
Generally gear pumps are used to pump:

• Petrochemicals: Pure or filled bitumen, pitch, diesel oil, crude oil, lube oil
etc.
• Chemicals: Sodium silicate, acids, plastics, mixed chemicals, isocyanates
etc.
• Paint and ink
• Resins and adhesives
• Pulp and paper: acid, soap, lye, black liquor, kaolin, lime, latex, sludge
etc.
• Food: Chocolate, cacao butter, fillers, sugar, vegetable fats and oils,
molasses, animal food etc.

External gear pump
The suction side is towards the portion whereas the gear

teeth come out of the mesh.
Clearances are
generally 10 microns
Unbalanced side load

on its bearing
Gear pumps are most

commonly used for the
hydraulic fluid power
applications

Lobe Pump
the lobes do not make any contact
Lobe contact is prevented by external timing

gears
can handle solids (e.g., cherries and olives),

slurries, pastes, and a variety of liquids
widely used in industries such as pulp and

paper, chemical, food, beverage,
harmaceutical and biotechnology etc

Internal Gear Pump

Gerotor Pump
consists of two rotors viz. inner and outer

rotor. The inner rotor has N teeth, and
the outer rotor has N+1 teeth

Vane Pumps
Gear pumps have a disadvantage of small leakage due to

gap between gear teeth and the pump housing. This
limitation is overcome in vane pumps
Capacity and pressure ratings of a vane pump are

generally lower than the gear pumps, but reduced
leakage gives an improved volumetric efficiency of
around 95%

Types of Vane Pumps
sliding vane- can run dry for short periods of time and can
handle small amounts of vapor
flexible vane- can handle only the small solids but create
good vacuum
external vane - can handle large solids
swinging vane, rolling vane pump etc.
The vane pumps are known for their

dry priming, ease of maintenance,
and good suction characteristics

Applications
• Aerosol and Propellants

• Aviation Service - Fuel Transfer, Deicing
• Auto Industry - Fuels, Lubes, Refrigeration Coolants
• Bulk Transfer of LPG and NH3
• LPG Cylinder Filling
• Alcohols
• Refrigeration - Freons, Ammonia
• Solvents
• Aqueous solutions

Unbalanced and balanced
vane pump
Unbalanced vane pump
Balanced Vane Pump

Adjustable vane pump

Piston pumps- Bent axis
piston pump

Piston pumps- Swash plate
piston pump

Piston pumps- Radial piston
pump

Remember- Components in
hydraulic and pneumatic system

Fluid Power Actuators

Three basic type of
control devices
• Direction control valve (control flow path)
- Check valve
- Shuttle valve
- 2 way, 3 way, 4 way DCV
• Pressure control valve (protect system)
• Flow control valve (speed control)

Directional control valves
classification
1. Type of construction:
• Check valves (ball/poppet)
• Spool valves
2. Number of ports:
• Two- way valves
• Three – way valves
• Four- way valves.

Directional control valves
classification
3. Number of switching position:
• Two – position
• Three - position
4. Actuating mechanism:
• Manual actuation
• Mechanical actuation
• Solenoid actuation
• Hydraulic actuation
• Pneumatic actuation
• Indirect actuation

Check Valve
Allow flow in one direction only
cracking pressure. -minimum upstream pressure at which

the valve operates
Right angle check valve

Inline check valve

Restriction check valve
application where free flow is

required in one direction and
restricted flow required in
another direction.

check valve

Spool valve
Connect / Disconnect two or more Ports by Shifting / Rotating a Spool
Normally closed and normally open :NO and NC
Valve closed
Valve opened by actuation

2 , 3 and 4 way spool valves
Three way valve: P to A

connected and T is blocked
Three way valve

in closed position

4 way valve
? But it shows 5 ports

Spool Positions

Position and ways- 2/4

Position and ways- 2/4 is it the
same

Valve actuation

Valve actuation

Valve actuation

Pressure control valve

Pressure relief valve
The pressure relief valves are used to protect the hydraulic

components from excessive pressure.
Direct type of relief valve



symbol


Unloading Valve

Combination Pump
Extend and retract
When no load-
high flow rate and low pressure-
just overcome friction
When loaded- high pressure

low volume

Sequence valve

Brake/Counter balance valve
It is used to maintain the

back pressure and to prevent
a load from failing

Schematic symbol

Pressure reducing valve

Pressure reducing valve

Tightens screw or bottle cap

Flow control valve

Flow control valve

Flow control valve

Flow control valve

Flow control valve

Flow control valve

Flow control valve

With load speed may vary

Pressure difference and flow
rate

Variation in load changes flow

Two types
Non pressure compensated

Pressure compensated

Under load- state 1

Increasing load- state 2

On adding more load

On reducing load

Control with FCV
Require DCV
And FCV
Manual operation required for varying actuators stroke
speed

Valves
Solenoid valves On/off

Proportional valves: flow variable, relatively cheaper
Servo valves: variable flow, costly

Solenoid valve and
proportional valve

Proportional control valve

Proportional valve and servo

Hysteresis in proportional and
servo control valve

Symbols for ports

Symbols

Hydraulic Circuits

Hydraulic / Pneumatic Control
System

Hydraulic / Pneumatic Control
System

Single Acting Cylinder Control

Double Acting Cylinder
Control

Double Acting Cylinder Contro

Regenerative Circuit



Displacement step diagram of
actuators

Cylinder Synchronising Circuit

Cylinder Synchronising Circuit

Circuit Design Problem

Circuit Design Approach



Pump power
P= pre x Q Watts
=pghxQ ; p=density
=yQH
y= specific weight N/m3
Electric motor power= P/efficiencies

1m3=1000 L

Hydraulic Circuit Analysis


Laminar / Turbulent

Friction Losses

Darcy-Weisbach Equation

Friction Losses in Laminar
Flow

Friction Losses in Turbulent
Flow

Moody Diagram

Losses in Valves & Fittings

K Factor for Valves & Fittings

Equivalent Length Technique

Equivalent Length Technique

Viscocity Dynamic: Poise
CGS

Viscocity
Kinenamatics:Stokes CGS

Practice Problem

Industrial Automation: BITS Pilani, Pilani Campus

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Industrial Automation

BITS Pilani, Pilani Campus

Replacing the human muscle power

electrical machines or diesel, petrol and steam engines

Not only these

BITS Pilani, Pilani Campus

the pressure in an enclosed fluid is uniform in all the

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Compressor- motor or engine

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

In general pumps speed is constant and it deliver equal volume

Power efficiency= output hydraulic power to the input

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

uses rotational kinetic energy to deliver the fluid

the delivery is not constant and varies according to the

generally used for low-pressure and high-volume flow

BITS Pilani, Pilani Campus

also known as positive displacement pump or piston pump

Small quantity and large pressure

Depending on the area of cylinder the pump delivers

BITS Pilani, Pilani Campus

In general he pump is placed over the fluid storage tank

pump creates negative

Cavitations reduces this max pump lift

BITS Pilani, Pilani Campus

The cavitation is the formation of vapor cavities in a liquid

Rapid change in pressure (at low pressures) causes it

Can be avoided at lower at lower flow velocities

Pump lift should be minimum to avoid cavitation and increase

BITS Pilani, Pilani Campus

the process of reduction of high source pressure to a lower

What will happen if V1 is closed

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

It is important to note that the positive displacement pumps

Unblocked- partially blocked- fully blocked

When fully blocked pressure increases weakest component

Important positive displacement pumps are gears pumps,

BITS Pilani, Pilani Campus

Generally gear pumps are used to pump:

BITS Pilani, Pilani Campus

The suction side is towards the portion whereas the gear

Unbalanced side load

Gear pumps are most

BITS Pilani, Pilani Campus

Lobe contact is prevented by external timing

can handle solids (e.g., cherries and olives),

widely used in industries such as pulp and

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

consists of two rotors viz. inner and outer