Design Hydraulic and Pneumatic Systems:

 Design hydraulic and pneumatic systems requires a deep understanding of fluid

mechanics, pressure, force, and motion. This guide will walk you through the key steps,
factors to consider, and tools that will help you create efficient and reliable systems.

1. Define the Application and System Requirements:

• What is the purpose of the system? (e.g., lifting, clamping, actuation, control)

• What are the required forces and motions? (e.g., lifting capacity, travel distance,
speed)

• What is the budget and desired level of complexity?

 Cont….
2. Select the Fluid:

• Hydraulics: Typically uses mineral oil-based fluids, but other fluids like synthetic oils,
water-based fluids, and fire-resistant fluids are also available.

• Pneumatics: Uses compressed air, which is readily available and safe to handle.

3. Design the Power Unit:

• Hydraulic: Requires a hydraulic pump to pressurize the fluid, typically powered by an

electric motor or internal combustion engine.

• Pneumatics: Requires an air compressor to provide compressed air.

 Cont….
4. Select and Design Components:

• Valves: Control the flow of fluid (e.g., directional control valves, pressure relief
valves, flow control valves)

• Actuators: Convert fluid pressure into linear or rotary motion (e.g., hydraulic
cylinders, pneumatic cylinders, hydraulic motors, pneumatic motors)

• Filters: Remove contaminants from the fluid to ensure smooth operation and prevent
wear.

• Sensors: Provide feedback on system parameters like pressure, position, and flow.

• Piping and Tubing: Transport the fluid from the power unit to the actuators and back.
 Cont…
5. Choose the Control System:

• Hydraulics: Can be controlled manually, electrically, or electronically.

• Pneumatics: Typically controlled by solenoid valves activated by electrical signals.

• Consider: Proportional control, servo control, and feedback mechanisms for precise
control.

6. Simulate and Analyze the System:

• Use software tools to simulate system performance and analyze potential issues.

• Assess fluid flow rates, pressure drops, power consumption, and cycle times.

• Identify areas for optimization to improve efficiency and reliability.

 Cont…
7. Prototype and Test the System:

• Build a prototype of the system to verify design calculations and functionality.

• Conduct rigorous testing under various operating conditions to ensure safety and
performance.

8. Implement and Commission the System:

• Install the system and connect it to the power source.

• Commission the system by performing final adjustments and calibration.

• Train operators on proper use and maintenance procedures.

Key considerations for designing hydraulic and pneumatic systems:
• Safety: Ensure fail-safe mechanisms and pressure relief valves are incorporated for
operator safety.

• Efficiency: Optimize component selection and design for maximum performance with
minimal energy consumption.

• Reliability: Choose high-quality components and implement robust maintenance

procedures to minimize downtime.

• Maintainability: Design the system for easy access and repair to reduce maintenance
costs.

• Cost: Consider the cost of components, installation, and ongoing maintenance when
making design choices.
 Design Electro-Hydraulic and Electro-Pneumatic Systems:
• Electro-hydraulic and electro-pneumatic systems blend the power of hydraulics and
pneumatics with the precision and versatility of electronics. These systems offer a
unique combination of high force, speed, and controllability, making them ideal for a
wide range of applications.

1. Defining the Application and System Requirements:

• What is the system's purpose? (e.g., automation, positioning, motion control)

• What are the required forces and motions? (e.g., lifting capacity, travel distance, speed,
accuracy)

• What is the operating environment? (e.g., temperature, humidity, contaminants, shock

and vibration)
 Cont…
• What are the control requirements? (e.g., manual, programmable, feedback control,
closed-loop systems)

• What is the desired level of automation and complexity?

2. Selecting the Fluid and Power Unit:

• Electro-Hydraulic: Typically uses mineral oil-based fluids, but synthetic oils and
other specialized fluids are available depending on the application. Requires a hydraulic
pump, often powered by an electric motor.

• Electro-Pneumatic: Uses compressed air, which is readily available and safe to

handle. Requires an air compressor.
 Cont…
3. Designing the Control System:

• Electronics: Choose the appropriate control platform (e.g., PLC, microcontroller, PC-
based control) based on the application's complexity and communication needs.

• Sensors: Integrate sensors to provide feedback for closed-loop control (e.g., position
sensors, pressure sensors, flow sensors).

• Actuators: Select suitable actuators, including hydraulic cylinders, pneumatic cylinders,

hydraulic motors, and pneumatic motors, for the desired motion profile.

• Valves: Utilize solenoid valves, controlled by the electronics, to regulate fluid flow and
direction.
 Cont…
• Interfacing: Design the interface between the electronics and the hydraulic/pneumatic
components (e.g., solenoid valve drivers, sensor interfaces).

Key Considerations for Designing Electro-Hydraulic and Electro-Pneumatic Systems:

• Control Precision: The precision of the control system directly impacts the accuracy of
the system. Choose the appropriate control platform and implement feedback loops for
high-precision applications.

• Response Time: The speed at which the system responds to control signals is crucial.
Select components that can achieve the desired response times, and consider factors like
fluid viscosity and actuator dynamics.
 Cont…
• Integration: Successfully integrating electronics, hydraulics, and pneumatics is vital.
Ensure proper communication, compatibility, and safety protocols are implemented.

• Safety: Incorporate safety features like fail-safe mechanisms, pressure relief valves,
and emergency stops to prevent accidents and protect operators.

• Maintenance: Consider the accessibility and ease of maintenance for long-term

reliability.

Advantages of Electro-Hydraulic and Electro-Pneumatic Systems:

• High force and power density: Ideal for applications requiring significant force and
power.
 Cont…
• Precise control: Enables fine control of motion and speed.

• Flexibility: Can be easily adapted to various applications with different force and motion
requirements.

• Reliability: Proven track record in industrial settings for durability and performance.

• Automation: Well-suited for automated systems

 Tracing and analyzing electro-hydraulic and electro-pneumatic systems:
• Tracing and analyzing electro-hydraulic and electro-pneumatic systems require a
systematic approach that involves understanding the flow of fluid, electrical signals, and
the interplay between components. Here's a breakdown of the process:

1. System Overview and Schematic Diagram:

• Identify the purpose: Determine what the system is designed to do (e.g., lifting,
clamping, positioning).

• Locate the schematic diagram: Find the system's schematic diagram which shows the
interconnected components and their relationships.

• Familiarize yourself with symbols: Understand the standard symbols used for hydraulic
and pneumatic components, electrical components, and control elements.
 Cont…
2. Tracing the Fluid Path (Hydraulic/Pneumatic):

• Start at the power source: Trace the flow of fluid from the pump (hydraulic) or
compressor (pneumatic) to the actuator.

• Follow the piping/tubing: Note the direction of flow indicated by arrows on the
schematic.

• Identify valves and their function: Each valve controls the flow of fluid, including
directional control valves, pressure relief valves, flow control valves, and solenoid valves.

• Observe the actuator: Determine the type of actuator (e.g., cylinder, motor) and its
connection to the fluid path.
Cont…
 Cont…
3. Tracing the Electrical Path:

• Locate the control system: Identify the control system (PLC, microcontroller, PC)
responsible for sending electrical signals to the system.

• Follow the wiring: Trace the wiring from the control system to the solenoid valves,
sensors, and other electrical components.

• Understand signal flow: Identify the signals (voltage, current) used for control,
feedback, and communication between components.

• Analyze the control logic: Determine the programming or logic that governs the
operation of the system, including the sequence of valve activations, sensor readings, and
feedback loops.
 Cont…
4. Analyzing System Behavior:

• Identify system states: Determine how the system operates in different states (e.g.,
extend, retract, hold, and stop).

• Analyze pressure and flow: Examine the pressure and flow characteristics of the
system in each state, taking into account factors like pump output, valve settings, and
actuator load.

• Evaluate response times: Assess the time it takes for the system to respond to control
signals and reach its desired state.

• Consider safety features: Analyze the fail-safe mechanisms and pressure relief valves
to ensure the system's safety.
 Cont…
5. Troubleshooting and Maintenance:

• Identify common problems: Analyze potential malfunctions based on symptoms like

fluid leaks, pressure drops, slow response times, or faulty control signals.

• Use diagnostic tools: Utilize pressure gauges, flow meters, multi meters, and data
loggers to measure and diagnose problems.

• Implement corrective actions: Repair leaks, replace faulty components, adjust valve
settings, or modify control logic to address identified issues.

Tools and Resources:

• Schematic diagrams: Obtain detailed schematics from the system's documentation.

 Cont….
• Component manuals: Refer to technical manuals for specific components to understand
their specifications, operation, and troubleshooting procedures.

• Diagnostic tools: Utilize industry-standard tools for measuring pressure, flow, voltage, and
other system parameters.

• Simulation software: Utilize software like FluidSIM and Simulink to model system
behavior and perform virtual troubleshooting.

• Online forums: Seek expert advice and troubleshooting tips from industry forums and
communities.
 Cont…
 Design of the circuit diagram
 Cont….
 Designation by numbers

o With this type of designation, elements are divided into groups. Group 0 contains the
elements for the power supply, groups 1,2,... Designate the individual control chains.
One group number is generally allocated for each cylinder.
 Cont….
 Designation by Letters

This type of designation is used primarily for a systematic development of circuit

diagrams. Here, limit switches are allocated to the cylinder, which acknowledges them.
Cont…
 Cont….
 The good manner arrangement of pneumatic and hydraulic components

• Physical arrangement of the elements is ignored.

• Draw the cylinders and directional control valves horizontally wherever possible.

• The energy flow within the circuit moves from the bottom to the top.

• Energy source can be shown in simplified form.

• Show elements in the initial position of the control. Identify actuated elements by a cam.

• Draw pipelines straight without cross-over wherever possible.

 Example
What are the specification of the job?
>Load to be Lifted — 1000 Kg.
>Load Travel Distance (Stroke Length) 50 cm
>Time Required to Reach Distance 10 cm/sec.
What Size of Cylinder Needed?
>Which side load to be lifted (piston or rod side)
>Select the working pressure (50 to 80 bar approx.)

> Calculate the Area of cylinder A=F/P

>Select Standard Bore and Rod size

 Cont…
Flow rate: is the volume of fluid passing a point in a given period of time.

Flow rate (L/min) = (Velocity (cm/min) × Area (𝑐𝑚2 )) /1000

Flow rate and rod speed: The speed at which a cylinder rod moves is determined by how
fast the pump can fill the volume behind the cylinder piston.

• The speed of cylinder rod (V) is calculated by dividing the oil flow rate (Q) by the piston
area (A) being acted upon.

• Rod speed (V) = Flow rate (Q)/ Piston area (A)

 Cont…
Extension speed

Q (l/min) × 1000 𝜋𝐷2

V (cm/s) =
𝐴𝑓 (𝑐𝑚2 ) × 60
where 𝐴𝑓 =
4
 Cont…
Retraction speed
Q (l/min) × 1000 𝜋𝐷2 𝜋𝑑 2
V (cm/s) =
𝐴𝑎 (𝑐𝑚2 ) × 60
where 𝐴𝑎 = −
4 4
 Cont…
Cylinder Selection Reasoning
What Capacity Pump is needed?
>Large Diameter Cylinder
>Maximum Cylinder Speed Required
*Operates at Low Pressure
>Flow Rate = (Cyl.Area x Stroke / Time)
*Require bigger pump for Speed

>Smaller Diameter Cylinder

>Next Standard Pump selected.

*Operates at High Pressure ' *Cubic Centimeter per revolution

*Small Bigger pump give Speed

>Cylinder Selected = 10 cm Bore

 Cont…
What Capacity of Electric Motor Needed?

>Calculate Power Required to Run Pump

>Power KW= (LPM x Pressure)/600

>Motor speed = (LPM / CC per Rev.of pump)

>Consider the Efficiency of Pump

>Shaft Size, Type of Electric Source.

 Cont…
 What size of reservoir
• The hydraulic reservoir is a container for holding the fluid required to supply the system,
including are serve to cover any losses from minor leakage and evaporation. The reservoir
can be designed to provide space for fluid expansion, permit air entrained in the fluid to
escape, and to help cool the fluid.
• In order to the suitable for the demand of heat dissipation and air separation, the oil
reservoir must be designed be as large as possible. Primarily size of reservoir is decided by
the pump delivery flow. By an imperial rule these are taken as
 V=3.5 for stationery installation Where V=Reservoir size in liter.
 V=1*Q………….For mobile installation Q=Pump delivery flow in liter per minute.