CAM and AUTOMATION
MCL 431
CAM AND AUTOMATION
Hydraulic Circuit Design
Dr. Sunil Jha
[email protected] Of ce: Block III/156
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 1
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CAM and AUTOMATION
Circuit Design Considerations
Safety of Operation
Pressure and Temperature Ratings
Interlocks for sequential operations
Emergency Shutdown features
Power Failure locks
Operation Speed
Environment conditions
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
CAM and AUTOMATION
Circuit Design Considerations
Meet Functional Requirements
Meet required performance speci cation
Life expectancy same as machine
Facilitate good maintenance practice
Compatibility with electrical and
mechanical components
Withstand operational hazards
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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CAM and AUTOMATION
Circuit Design Considerations
Ef ciency of Operation
Keep system Simple, Safe and Functional
Access to parts need repair or adjustment
Design to keep Min operational cost
Design to prevent and remove
contamination.
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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CAM and AUTOMATION
Q1
Circuit Design Problem
In a Sheet metal forming press. The shape to be
formed is hemispherical cup of radius 15 cm in 2
mm thick mild steel sheet. The force required to
deform sheet is 8 kN. The forming hammer should
approach job from a distance of 30 cm. The
production rate required is 240 components/hr.
Calculate and suggest the following speci cations
of the various hydraulic components used:
Hydraulic Cylinder (bore & length) La
Pump pressure and ow rate
Electric motor HP considering 75% pump ef ciency
Reservoir size
Size of pump inlet and discharge tubing
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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CAM and AUTOMATION
Circuit Design Approach
What are the speci cations of the job?
Force requirement – 8 kN
Length of work stroke – 15 cm
Production rate – 240 comp/hr
What Size of Cylinder is needed? 8 kN
Force known.
Cylinder Area & Operating Pressure
must be selected. F = PA
Standard bore and rod size cylinders
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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CAM and AUTOMATION
Circuit Design Approach
What Size of Cylinder is needed?
Large Diameter Cylinder
Small Diameter Cylinder P Q
Cylinder selected = 50 mm bore
Find Pressure and then select suitable pump
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
CAM and AUTOMATION
Circuit Design Approach
What Capacity Pump is needed?
Max Cylinder Speed required
Flow rate = (Cyl Area)x(Stroke)/(time)
Pump selection
What size of Electric Motor needed?
Calculate power required to run Pump
Consider ef ciency of pump
Shaft size, type and electric source
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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CAM and AUTOMATION
Circuit Design Approach
What Size reservoir should be used?
2.5-3.0 times the pump capacity (l/min)
Size of pump inlet?
Inlet ow velocity = 60-150 cm/sec
Size of Discharge tubing?
Outlet ow velocity = 200 - 450 cm/sec
Relief valve selection
Pressure range
Valve port size
Direction Control valve
Based on function
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi
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CAM and AUTOMATION
Control of a Hydraulic Motor
Hydraulic Motor – Rotary Motion
Motor Rotate
Clockwise
Motor Rotate
Antilockwise
Spring Centre Position
Motor hydraulically
locked
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 10
CAM and AUTOMATION
Hydraulic Motor Braking
Hydraulic motor may be driving Machine having a large inertia
Creates Flywheel effect.
Stopping motor, acts as a pump
Circuit is designed to provide uid to
the motor while it is pumping
Provisions should be made for
discharge uid from motor to be
returned to Tank
This would stop motor without damaging
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 11
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CAM and AUTOMATION
Hydraulic Motor Braking
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 12
CAM and AUTOMATION
Hydraulic Motor Braking
RV2
A C
B D
DCV
RV1
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 13
CAM and AUTOMATION
Q2
Circuit Design Problem
Design a hydraulic circuit for a shaper machine of size 250 mm without using
ow control valve. The ram should perform cutting during extension stroke with
a speed of 1.6 m/min and return at 4 m/min. The maximum cutting force on ram
is 25kN. The cutter should approach and leave the work piece as per Figure
below. Piston Area = 2000 sq. mm. Attempt the following
b a
• Draw the hydraulic circuit for the shaper machine. State the position of
DCV for cutting and return motion
• Piston Rod Area (sq. mm)
• Pump pressure and ow rate
• Electric motor HP considering 72% pump ef ciency
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 14
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CAM and AUTOMATION
Q3
Circuit Design Problem
A hydraulic motor is required to deliver 1.85 kNm
torque at 1800 rpm. The mechanical ef ciency of
hydraulic motor is 68%. Calculate and suggest the
following speci cations of the various hydraulic
components used:
• Pump pressure and ow rate
• Electric motor HP considering 75% pump ef ciency
• Reservoir size
• Size of pump inlet and discharge tubing
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 15
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CAM and AUTOMATION
Q4
Problem
Hydraulic Jack
450 kg
15 cm 5
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 16
CAM and AUTOMATION
Q4
Problem
Hydraulic Jack
a b
A1
A2
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 17
CAM and AUTOMATION
Q4
Problem
An operator makes one complete cycle per second using
the hydraulic jack as sown in Figure. Each complete cycle
consists of two pump cylinder strokes (intake and power). The
pump cylinder has a 25 mm diameter piston and the load
cylinder has a 80 mm diameter piston. If the average hand
force is 10 kg during the power stroke,
a) How much load can be lifted?
b) How many cycles are required to lift the load 25 cm assuming no
oil leakage? The pump piston has a stroke of 5 cm.
c) What is output HP assuming 80% ef ciency of the system?
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 18
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CAM and AUTOMATION
Q5
Problem
A 10 kN weight is to be lowered
by a vertical cylinder as shown in
Fig. The cylinder has a 75 mm
diameter piston and a 50 mm
diameter rod. The weight is to
decelerate from 100 m/min to a
stop in 0.5 s. Determine the
required pressure in the rod end
of the cylinder during the
deceleration motion.
Sunil Jha, Department of Mechanical Engineering, I.I.T. Delhi 19
