Fluid Power - Hydraulics Fundamentals, Model 6080
Fluid PowerHydraulics FundamentalsCourseware Sample30794-F0
Order no.:30794-00First EditionRevision level: 01/2015By the staff of Festo Didactic Festo Didactic Ltée/Ltd, Quebec, Canada 1996Internet: www.festo-didactic.come-mail: did@de.festo.comPrinted in CanadaAll rights reservedISBN 978-2-89289-349-6 (Printed version)ISBN 978-2-89640-651-7 (CD-ROM)Legal Deposit – Bibliothèque et Archives nationales du Québec, 1996Legal Deposit – Library and Archives Canada, 1996The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limitedgeographically to use at the purchaser's site/location as follows.The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location andshall also be entitled to use parts of the copyright material as the basis for the production of his/her owntraining documentation for the training of his/her staff at the purchaser's site/location withacknowledgement of source and to make copies for this purpose. In the case of schools/technicalcolleges, training centers, and universities, the right of use shall also include use by school and collegestudents and trainees at the purchaser's site/location for teaching purposes.The right of use shall in all cases exclude the right to publish the copyright material or to make thisavailable for use on intranet, Internet and LMS platforms and databases such as Moodle, which allowaccess by a wide variety of users, including those outside of the purchaser's site/location.Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming andtransfer to and storage and processing in electronic systems, no matter whether in whole or in part, shallrequire the prior consent of Festo Didactic GmbH & Co. KG.Information in this document is subject to change without notice and does not represent a commitment onthe part of Festo Didactic. The Festo materials described in this document are furnished under a licenseagreement or a nondisclosure agreement.Festo Didactic recognizes product names as trademarks or registered trademarks of their respectiveholders.All other trademarks are the property of their respective owners. Other trademarks and trade names maybe used in this document to refer to either the entity claiming the marks and names or their products.Festo Didactic disclaims any proprietary interest in trademarks and trade names other than its own.
Saafety andd Commmon SymmbolsThe foollowing safetty and common symbols mmay be usedd in this manuual and onthe equipment:SymbolSDescriptionDANGER inndicates a hazaard with a highh level of risk wwhich, if notavoided, will result in deatth or serious injjury.WARNING indicates a hazzard with a meedium level of rrisk which,if not avoideed, could resultt in death or seerious injury.CAUTION indicates a hazzard with a low level of risk whhich, if notavoided, coould result in miinor or moderaate injury.uwithout thhe Caution, riskk of danger sign ,CAUTION usedardous situatioindicates a hazard with a ppotentially hazaon which,if not avoideed, may result in property dammage.Caution, risk of electric shhockCaution, hoot surfaceCaution, risk of dangerCaution, lifting hazardCaution, haand entanglemeent hazardNotice, non-ionizing radiattionDirect curreentAlternating currentBoth direct and alternatingg currentThree-phasse alternating ccurrentEarth (ground) terminal
Safety and Common SymbolsSymbolDescriptionProtective conductor terminalFrame or chassis terminalEquipotentialityOn (supply)Off (supply)Equipment protected throughout by double insulation orreinforced insulationIn position of a bi-stable push controlOut position of a bi-stable push controlWe invite readers of this manual to send us their tips, feedback andsuggestions for improving the book.Please send these to did@de.festo.com.The authors and Festo Didactic look forward to your comments.
Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VCourseware OutlineHydraulics Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIIElectrical Control of Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . XHydraulics Applications – PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIIIHydraulics Applications – Servo-Proportional Controls . . . . . . . . . . . . . . XVSample Exercise from Hydraulics FundamentalsEx. 2-1 Pressure Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Sample Exercise from Electrical Control of Hydraulic SystemsEx. 2-3 Basic Electrically-Controlled Hydraulic System . . . . . . . . . . . . . . . 21Sample Exercise from Hydraulics Applications – PLCEx. 6Counting of Hydraulic Actuator Cycles . . . . . . . . . . . . . . . . . . . . . . 35Sample Exercise from Hydraulics Applications – Servo-Proportional ControlEx. 1Proportional Directional Control Valves . . . . . . . . . . . . . . . . . . . . . 47Other Samples Extracted from Electrical Control of Hydraulic SystemsUnit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Instructor Guide Sample Extracted from Hydraulics FundamentalsUnit 2 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71BibliographyIII
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IntroductionThe Lab-Volt Hydraulics Training System, Model 6080, is designed to familiarizestudents with the fundamentals of hydraulic energy and its controlled application.It consists of an introductory and an advanced training program demonstratingmanual, electrical and PLC control of hydraulic systems.The basic trainer demonstrates the basic principles of hydraulics. It comes with ahydraulic pump, a tank, a hydraulic motor, cylinders, flow control valves, directionalcontrol valves, and pressure gauges. Also provided is a work surface consisting ofa solid-metal perforated plate hinged to a drip tray. Lying flat over the drip tray, ortiltable at 45(, the work surface provides a large area on which the components canbe mounted. Mounting and removal of the components is especially easy withpush-lock fasteners that snap effortlessly into the perforations of the work surface.Additional components can be added to the basic trainer to demonstrate electricaland PLC control of hydraulic systems. The additional components required forelectrical control are time-delay relays, counter relays, sensors, and pilot lamps.Those required for PLC control are a programmable logic controller (PLC) and anextra work surface designed to mount on the main work surface.The courseware is structured in four separate courses to form a completeeducational program in hydraulic control:The course entitled “Hydraulics Fundamentals” covers the theory, generation,storage, and usage of hydraulic energy. The creation of pressure by applying forceto a confined liquid is discussed. The usefulness of fluid pressure and velocity isexamined, and the relationship between flow rate, velocity, and power are defined.The basic types of hydraulic circuits are introduced. Finally, a methodical approachto troubleshooting is outlined, based on the first principles of hydraulics.The course entitled “Electrical Control of Hydraulic Systems” covers basicelectricity, ladder diagrams, limit switches, standard industrial relays, and solenoidoperated directional valves. Functional electrically-controlled hydraulic systems arestudied, assembled, and tested. Students then use the acquired knowledge todesign their own systems and to simulate the operation of typical industrialsystems.The course entitled “Hydraulics Applications - PLC” explores the use for PLCs inhydraulic systems. Students begin with a revision of the basic PLC instructions.Functional PLC-controlled hydraulic systems are then studied, assembled, andtested. Students are invited to troubleshoot an industrial-type clamp and worksystem based on the principles of hydraulics and PLC. Finally, students use theacquired knowledge to design their own systems to simulate the operation of typicalindustrial applications.Finally, the course entitled “Hydraulics Applications - Servo-proportional Control”deals with PID control of hydraulic motor speed and cylinder position.V
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Courseware OutlineHYDRAULICS FUNDAMENTALSUnit 1Introduction to HydraulicsAn introduction to hydraulic circuits. Safety rules to follow when using theLab-Volt Hydraulics Trainer.Ex. 1-1Familiarization with the Lab-Volt Hydraulics TrainerIdentification of the various system components. Safety rules tofollow when using the Lab-Volt Hydraulics Trainer.Ex. 1-2Demonstration of Hydraulic PowerLifting up the hydraulic Power Unit using a small-bore cylinder.Investigation of a basic hydraulic circuit.Unit 2FundamentalsBasic concepts of hydraulics. Creation of pressure by applying force to aconfined fluid. Relationship between flow rate, velocity, and power.Ex. 2-1Pressure LimitationDesign and operation of a relief valve. Determining the oil flowpath in a circuit using a relief valve. Connection and operationof a circuit using a relief valve.Ex. 2-2Pressure and ForceVerifying the formula F P x A using a cylinder and a loadspring. Discovering what happens to a cylinder when equalpressures are applied to each side of its piston. Pressuredistribution in a cylinder in equilibrium of forces. Measuring theweight of the hydraulic Power Unit given the pressure requiredto lift it.Ex. 2-3Flow Rate and VelocityDesign and operation of a Flow Control Valve, NonCompensated . Relationship between flow rate and velocity.Connection and operation of meter-in, meter-out, and bypassflow control circuits.Ex. 2-4Work and PowerDefinition of the terms “work” and “power”. Relationshipbetween force, work, and power. Calculating the work, power,and efficiency of the circuit used to lift the hydraulic Power Unit.VII
Courseware OutlineHYDRAULICS FUNDAMENTALSUnit 3Basic CircuitsConnection and operation of simple, practical hydraulic circuits.Design and operation of a Directional Valve, Lever-Operated .Ex. 3-1Cylinder ControlControl of the direction, force, and speed of a cylinder. Designand operation of a Directional Valve, Lever-Operated . Effect ofa change in system pressure and flow rate on the force andspeed of a cylinder.Ex. 3-2Cylinders in SeriesDescription of the operation of a series circuit. Starting andstopping two cylinders at the same time by connecting them inseries. Demonstration of pressure intensification in a seriescircuit.Ex. 3-3Cylinders in ParallelDescription of the operation of a parallel circuit. Extensionsequence of parallel cylinders having differing bore sizes.Synchronizing the extension of parallel cylinders using a FlowControl Valve, Non Compensated .Ex. 3-4Regenerative CircuitsDesign and operation of a regenerative circuit. Effect ofregeneration on cylinder force and speed.Unit 4Functional CircuitsConnection and operation of functional hydraulic circuits usingaccumulators, hydraulic motors, Pressure Reducing Valves, and remotelycontrolled Relief Valves.Ex. 4-1AccumulatorsDescription of the general types of accumulators. Howaccumulators can be used in auxiliary power, emergencypower, leakage compensation, and shock suppression. Safetyrequirements for accumulator circuits.Ex. 4-2Hydraulic Motor CircuitsDesign and operation of a hydraulic motor. Calculating thetorque and speed of a hydraulic motor. Effect of a change inflow rate or pressure on motor operation.VIII
Courseware OutlineHYDRAULICS FUNDAMENTALSEx. 4-3Pressure Reducing ValvesDesign and operation of a Pressure Reducing Valve.Connection and operation of a clamp and bend circuit using aPressure Reducing Valve.Ex. 4-4Remotely-Controlled Relief ValvesHow to control a Relief Valve remotely. Connection andoperation of a circuit using a remotely-controlled valve to controlthe tonnage of a press cylinder.Unit 5TroubleshootingDeveloping a methodical approach for testing the main components of ahydraulic system, based on the manufacturer specifications and on thefirst principles of hydraulics. Observing the effects of temperature changeson the operating characteristics of a hydraulic system.Ex. 5-1Hydraulic PumpsBasic operation of a hydraulic pump. Using manufacturer pumpspecifications to test a pump. The effects of oil temperature onflow rate and volumetric efficiency.Ex. 5-2Directional Valve TestingShowing normal leakage of a directional valve. Evaluating thecondition of a directional valve according to the amount ofleakage flow.Ex. 5-3Flowmeter AccuracyVerifying the accuracy of a Flowmeter. Determining the effectof temperature on Flowmeter accuracy.Ex. 5-4Effects of Temperature on System OperationThe effects of temperature changes on pressure drop andcircuit flow rate.Appendices ABCDEquipment Utilization ChartCare of the Hydraulics TrainerConversion FactorsHydraulics and Pneumatics Graphic SymbolsBibliographyWe Value Your Opinion!IX
Courseware OutlineELECTRICAL CONTROL OF HYDRAULICS SYSTEMSUnit 1Introduction to Electrical Control of Hydraulic SystemsAn introduction to electrically-controlled hydraulic systems. Description ofthe function of each part of an electrical control circuit.Ex. 1-1Familiarization with the EquipmentIdentification of the components used for electrical control of theLab-Volt Hydraulics Trainer. Classifying these components asinput element, controller element, or actuating mechanism.Unit 2Electrical ConceptsBasic concepts of electricity. How to read, draw, and connect simpleladder diagrams.Ex. 2-1Basic ElectricityMeasurement of the voltage, resistance, and current in anelectrical control circuit. Connection and operation of anelectrical control circuit. Safety rules to follow when using theLab-Volt Hydraulics Trainer.Ex. 2-2Ladder DiagramsDefinition of a ladder diagram. Description of how a ladderdiagram operates and how it relates to the hydraulic equipment.Rules for drawing ladder diagrams. Connection and operationof basic ladder diagrams using series (AND) logic, parallel(OR) logic, and control relays.Ex. 2-3Basic Electrically-Controlled Hydraulic SystemDescription and operation of a magnetic proximity switch.Connection and operation of a one-cycle reciprocation system.Utilization of a holding relay contact to maintain the current toa directional valve solenoid after the START pushbutton isreleased.Unit 3Functional SystemsConnection and operation of functional electrically-controlled hydraulicsystems.X
Courseware OutlineELECTRICAL CONTROL OF HYDRAULICS SYSTEMSEx. 3-1Hydraulic Sequencing of CylindersDescription and operation of a sequence valve. Connection andoperation of a clamp and work system sequenced by asequence valve. Description and operation of a mechanical limitswitch.Ex. 3-2Electrical Sequencing of CylindersDescription and operation of a hydraulic pressure switch.Connection and operation of a clamp and work systemcontrolled by electrical means.Ex. 3-3Speed Regulation and Braking of Hydraulic MotorsDescription and operation of a pressure-compensated flowcontrol valve. Connection and operation of a speed regulationsystem that uses a pressure-compensated flow control valve tomaintain a constant motor speed as the system pressurechanges. Connection and operation of a motor braking systemthat uses a sequence valve to slow down a motor beforestopping it.Ex. 3-4Continuous Reciprocation with Dwell PeriodDescription and operation of a time-delay relay. Connection andoperation of a continuous reciprocation system that uses atime-delay relay to hold (dwell) a cylinder in a pre-determinedposition for some period of time.Unit 4Industrial ApplicationsConnection, design, and operation of industrial electrically-controlledhydraulic systems.Ex. 4-1Drilling SystemDescription and operation of a photoelectric switch. Steps thatmake up an industrial drilling process. Connection andoperation of an electrically-controlled hydraulic systemsimulating the operation of an industrial drilling machine.Ex. 4-2Safety CircuitsThe purpose and use of safety circuits in electrically-controlledhydraulic systems. Two-hand safety circuits. Connection andoperation of a basic two-hand safety circuit and a two-hand,non-tie-down safety circuit.XI
Courseware OutlineELECTRICAL CONTROL OF HYDRAULICS SYSTEMSEx. 4-3Counting of Actuator CyclesDescription and operation of a time-delay relay. Extension andretraction of a cylinder a definite number of times using anelectrical counter. Measurement of the rotation speed of ahydraulic motor using an electrical counter.Ex. 4-4Multi-Pressure SystemsUtilization of a solenoid-operated directional valve as apressure selector valve to select between two or moreoperating pressures. Designing a three-pressure level systemsimulating a spring testing bench.Ex. 4-5Rapid Traverse-Slow Feed SystemsExtension of a cylinder at two different speeds in different partsof its stroke. Designing a two-speed system simulating a rapidtraverse-slow feed system.Unit 5TroubleshootingBasic techniques used in troubleshooting the electrically-controlledhydraulic systems.Ex. 5-1Troubleshooting Electrical Control CircuitsDescription of the voltmeter and ohmmeter methods oftroubleshooting an electrical control circuit. Location ofinstructor-inserted faults in the electrical section of anelectrically-controlled hydraulic drilling system.Ex. 5-2Troubleshooting Electrically-Controlled Hydraulic SystemsLearning an efficient troubleshooting method for locating faultsin an electrically-controlled hydraulic system. Location ofinstructor-inserted faults in the hydraulic and electrical sectionsof an electrically-controlled clamp and grind system.AppendicesABCDEEquipment Utilization ChartCare of the Hydraulics TrainerConversion FactorsHydraulics and Pneumatics Graphic SymbolsTime-Delay Relay / Counter SpecificationsBibliographyWe Value Your Opinion!XII
Courseware OutlineHYDRAULICS APPLICATIONS – PLCEx. 1Programmable Logic Controller ReviewRevision of the PLC relay-type instructions. Entering and testing aprogram that uses relay-type instructions to control the turning on andturning off of two lamps.Ex. 2Timer InstructionsRevision of the PLC timer instructions. Entering and testing a program thatuses timer-on instructions to turn on three lamps in a programmed orderand for a definite period of time.Ex. 3Counter InstructionsRevision of the PLC counter instructions. Entering and testing a programthat uses two counters in cascade to turn on a lamp after another lamphas turned on a definite number of times.Ex. 4Latching and Comparison InstructionsRevision of the PLC latching and comparison instructions. Entering andtesting a program that uses latching and counter-driven comparisoninstructions to turn on a lamp after another lamp has blinked a definitenumber of times.Ex. 5Time-Delay Control of Hydraulic ActuatorsConnection and operation of a PLC-controlled hydraulic system thatcontinuously reciprocates a cylinder and makes it dwell in two predetermined positions for some period of time.Ex. 6Counting of Hydraulic Actuator CyclesConnection and operation of a PLC-controlled hydraulic system thatmakes a motor rotate 1000 turns and then reciprocates a cylinder10 times.Ex. 7Safety Control of Hydraulic ActuatorsConnection and operation of a PLC-controlled hydraulic system that usesa STOP/RESET pushbutton, a pressure switch, and an alarm lamp toprovide safety control of a press cylinder.Ex. 8PLC-Controlled Clamp and Work SystemConnection and operation of an industrial-type clamp and work system.Monitoring the pressure applied behind the piston of the clamp cylinder toensure the workpiece remains firmly clamped while being worked on.XIII
Courseware OutlineHYDRAULICS APPLICATIONS – PLCEx. 9TroubleshootingLocation of instructor-inserted faults in the hydraulic and PLC-controlsections of the clamp and work system studied in Exercise 8.Ex. 10Designing a PLC-Controlled Pun
Lab-Volt Hydraulics Trainer. Ex. 1-1 Familiarization with the Lab-Volt Hydraulics Trainer Identification of the various system components. Safety rules to follow when using the Lab-Volt Hydraulics Trainer. Ex. 1-2 Demonstration of Hydraulic Power Lifting up the hydraulic Power Unit using a small-bore cylinder. Investigation of a basic hydraulic .
me2305 applied hydraulics and pneumatics department of mechnical engineering [p.madhan kumar-ap/mech] page 1 me 2305 – applied hydraulics and pneumatics iii year v sem., unit - i hydraulics - fluid power systems and fundamentals part – a 1.1. define fluid power.
HYDMOD3 is an integrated computer model of comprehensive drilling hydraulics. It covers detailed hydraulics, from surge and swab to nozzle selection - almost every aspect of hydraulics. The LI window-style program graphically displays the data and allows the user to quickly optimize the hydraulics - program.
Fundamentals of Fluid Mechanics. 1 F. UNDAMENTALS OF . F. LUID . M. ECHANICS . 1.1 A. SSUMPTIONS . 1. Fluid is a continuum 2. Fluid is inviscid 3. Fluid is adiabatic 4. Fluid is a perfect gas 5. Fluid is a constant-density fluid 6. Discontinuities (shocks, waves, vortex sheets) are treated as separate and serve as boundaries for continuous .
L M A B CVT Revision: December 2006 2007 Sentra CVT FLUID PFP:KLE50 Checking CVT Fluid UCS005XN FLUID LEVEL CHECK Fluid level should be checked with the fluid warmed up to 50 to 80 C (122 to 176 F). 1. Check for fluid leakage. 2. With the engine warmed up, drive the vehicle to warm up the CVT fluid. When ambient temperature is 20 C (68 F .
Motion of a Fluid ElementMotion of a Fluid Element 1. 1. Fluid Fluid Translation: The element moves from one point to another. 3. 3. Fluid Fluid Rotation: The element rotates about any or all of the x,y,z axes. Fluid Deformation: 4. 4. Angular Deformation:The element's angles between the sides Angular Deformation:The element's angles between the sides
Fluid Mechanics Fluid Engineers basic tools Experimental testing Computational Fluid Theoretical estimates Dynamics Fluid Mechanics, SG2214 Fluid Mechanics Definition of fluid F solid F fluid A fluid deforms continuously under the action of a s
Jul 09, 2015 · Tiny-Fogger/Tiny F07, Tiny-Compact/Tiny C07 Tiny-Fluid 42 Tiny FX Tiny-Fluid 42 Tiny S Tiny-Fluid 43 Unique 2.1 Unique-Fluid 43 Viper NT Quick-Fog Fluid 44 Viper NT Regular-Fog Fluid 45 Viper NT Slow-Fog Fluid 46 Martin K-1 Froggy’s Fog K-razy Haze Fluid 47 Magnum 2000 Froggy’s Fog Backwood Bay Fluid 48
Test Report No.: E2552 .04 -501 -47 Report Date: 07/12/16 Page 6 of 9 7.0 Test Results : The temperature during testing was 20.5 C ( 69 F). The results are tabulated as follows: Test Specimen #1 : Title of Test Results Allowed Note Operating Force, per ASTM E 2068 Initiate motion: 45 N ( 10 lbf) 60 N ( 13 lbf) max. Maintain motion:
