A PROJECT REPORT ON

INJECTION MOULDING MACHINE

SUBMITTED BY- SHAILESH GUPTA
DPMT
6th SEMESTER

HALL TICKET NO. 220503095

(YEAR 2022-2025)

UNDER THE GUIDENCE OF

MR. T.B. SETHURAMAN
(PRODUCTION MANAGER)
MOTHERSON AUTOMOTIVE TECHNOLOGIES & ENGINEERING LTD.PUNE
(A DIV.OF MOTHRSON SUMI SYSTEMS LTD.)

SUBMITTED TO:

CENTRAL INSTITUTE OF PETROCHEMICALS ENGINEERING &

TECHNOLOGY LUCKNOW
Industrial Area, Amausi B-27,CIPET,Nadarganj,Lucknow, Uttar Pradesh
226008
PHONE NO: 052222 243 6227,7607194014

Website: www.cipet.gov.in
E-mail: [email protected]

Central Institute of Petrochemicals Engineering & Technology (CIPET)

Department of Chemicals & Petrochemicals
Ministry of Chemicals & Fertilizers, Govt. of India
 BONAFIED CERTIFICATE

This is certify that the work reported in this project complied “INJECTION
MOULDING MACHINE” completed by “ SHAILESH GUPTA (Hall Ticket No.
220503095)” student of CIPET IPT-LUCKNOW during the year 2022-25 In
fulfilment for the award of DIPLOMA IN PLASTIC MOULD TECHNOLOGY (DPMT)
issued by CENTRAL INSTITUTE OF PETROCHEMICALS ENGINEERING &
TECHNOLOGY
(CIPET).

Course In-Charge -Mr.Rajil Sinha

Training In-Charge -Dr.Rajesh Panda

Mr. Dr.SN Yadav

Principal Director & Head

Industrial area, Amausi B-27,CIPET Road ,Nadarganj, sarojaninagar Lucknow, Uttar

pradesh 226008
Phone: 05222243 6227,7607194014
E-mail: [email protected]
Website: www.cipet.gov.in

ACKNOWLEDGEMENT
We own the deep sense of gratitude to our guide
Mr. T.B. SETHURAMAN “INJECTION MOULDING MACHINE’
whose heartily co-operation & encouragement inspire us in
creating successfully throughout the completion. He/ she has
given us his/her valuable suggestion and helpful criticism for which
we are thankful to him.
We have great pleasure in expressing our sincere thanks to for his
encouragement & noble co-operation from conception to completion
of this project.
Lastly, we would like to thank all technical persons of all
department for their sustained efforts and help in reaching our
coveted goal.

SUBMITTED BY
SHAILESH GUPTA
DPMT 6thSEMESTER
HALL TICKET NO. 220503095
(YEAR 2022-2025)
Signature of HOD :
BONAFIED CERTIFICATE :
This is certified that ‘(SHAILESH GUPTA HALL TICKET No. 220503095)’ of
Diploma in Plastic Mould Technology (2023-2024) student of CIPET IPT
LUCKNOW successfully completed the project on INJECTION MOULDING
MACHINE in our company “MOTHERSON AUTOMOTIVE TECHNOLOGIES &
ENGINEERING LTD” PUNE.

UNDER THE GUIDENCE OF

MR. T.B. SETHURAMAN
 Production Manager Signature of HOD
Motherson Automotive Technologies &
Engineering,

PUNE

Supported By:
SR. ENGINEER
Mr. RAMESHWAR WAGHCHOURE Signature of ENGINEER

CONTENTS
• INTRODUCTION…………………………………………

▪ 1 Types of Injection Moulding

▪ 2 Equipment
▪ 2.1 Injection moulding machine
▪ 2.1.1 Horizontal or vertical machines
▪ 2.1.2 Clamping unit

2.2Injection mould

▪ 3 Injection process
▪ 3.1 Injection Moulding Cycle
▪ 3.2 Moulding trial
▪ 3.3 Moulding defects

▪ 1- Raw Materials
▪ 2- Tooling
▪ 3- Cost
▪ 4- Advantages
▪ 5- Disadvantages
▪ 6- Applications

• History
• Reference
 SYSTEM AT OUR WORK PLACE

Our aim at Motherson Automotive Technologies & Engineering is to

bring the company the highest level of industries performance, which calls for
a whole, hearted level of each one of us. Our work place management and the
production process are organized around the following principle.

• 5’s
• TS
• EMS
• Kaizen
• Poke yoke
• JIT
• Kanban

5’s
1’S’ SEIRI - SORTING OUT

2’S’ SEITON - SYSTEMATIC ARRANGEMENT

3’S’ SEISO - SPIC AND SPAN/ CLEANING

4’S’ SEIKETSU - STANDARDISATION

5’S’ SHITSUKE - SELF DISCIPLINE

 SAFETY POLICY
• Motherson Automotive Technologies & Engineering is
concerned about the safety of its employees and interested parties and
therefore committed to:
• Deploy all necessary measures towards safety through top to bottom in
an integrated manner on sustainable basis.
• Identify control and reduce contributory factors affecting safety as step
towards continual improvement Completely with all statutory and
regulatory requirements relevant to safety of all Generated awareness &
effective involvement of all employees towards safety.

PROMINENT CUSTOMERS;-
 Volkswagen
Locations: South Africa, Mexico, Brazil, Russia,
Germany, India
Products dealt with: Interior Parts & Assembly, Engine
Modules

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Locations: India
Products dealt with: Interior Parts & Assembly

Mahindra and Mahindra Limited is an Indian multinational car manufacturing corporation headquartered
in Mumbai, Maharashtra, India.

Near Jay Towers, Pune Bombay Road, Chinchwad, Pimpri-Chinchwad, Maharashtra 411035

QUALITY CERTIFICATE
• TS 16949
• ISO 14001
• ISO 18001
 OUR PRODUCTS

HISTORY OF MOULDING

In 1868, John Wesley Hyatt became the first to inject hot celluloid into a mould,
producing billiard balls. He and his brother Isaiah patented an injection moulding
machine that used a plunger in 1872, and the process remained more or less the
same until 1946, when James Hendry built the first screw injection moulding
machine, revolutionizing the plastics industry. Roughly 95% of all moulding
machines now use screws to efficiently heat, mix, and inject plastic into moulds.
INTRODUCTION
Injection moulding (or Injection Moulding) is a manufacturing technique for
making parts from plastic material. Molten plastic is injected at high pressure into
a mould, which is the inverse of the desired shape. The mould is made by a mould
maker (or toolmaker) from metal, usually either steel or aluminum, and precision-
machined to form the features of the desired part. Injection moulding is very
widely used for manufacturing a variety of parts, from the smallest component to
entire body panels of cars. It is the most common method of production, with
some commonly made items including bottle caps and outdoor furniture.

Types of Injection Moulding

Main article: Types of injection moulding

▪ Reaction injection moulding

▪ Liquid injection moulding
▪ Gas assist injection moulding
▪ Co-injection moulding
▪ 2-Shot Injection Moulding
▪ Fusible core injection moulding
▪ Rapid injection moulding

INJECTION MOULDING
Process: Injection moulding cycle Reaction injection moulding, Reinforced reaction
injection moulding, Liquid injection moulding, Gas assist injection moulding, Co-
injection moulding, 2-shot injection moulding, Fusible core injection moulding,
Rapid injection moulding, Micro injection moulding

Equipment: Injection moulding machine(Vertical, Horizontal), Injection moulding

press, Injection mould (Hot runner, Cold runner), Injection unit (Injection ram,
Injection screw), Clamping unit (Toggle , Hydraulic, Hydromechanical), Plunger
injection moulding, Injection moulding machine manufacturers, Types of injection
moulding machines.
Equipment

Injection moulding machine

Injection moulding machines, also known as presses, hold the moulds in
which the components are shaped. Presses are rated by tonnage, which
expresses the amount of clamping force that the machine can generate. This
pressure keeps the mould closed during the injection process. Tonnage can
vary from less than 5 tons to 6000 tons, with the higher figures used in
comparatively few manufacturing operations.

Horizontal or vertical machines

Injection moulding machines can fasten the moulds in either a horizontal or
vertical position. The majority is horizontally oriented but vertical machines
are used in some niche applications such as insert moulding, allowing the
machine to take advantage of gravity.

CLAMPING UNIT
Main article: Clamping unit

Machines are classified primarily by the type of driving

systems they use: hydraulic, electric, or hybrid. Hydraulic
presses have historically been the only option available
to molder’s until Nisei introduced the first all-electric
machine in 1983. The electric press, also known as
Electric Machine Technology (EMT), reduces operation
costs by cutting energy consumption and also addresses
some of the environmental concerns surrounding the
hydraulic press. Electric presses have been shown to be
quieter, faster, and have a higher accuracy, however the
machines are more expensive. Hybrid injection moulding
machines take advantage of the best features of both
hydraulic and electric systems. Hydraulic machines are
 the predominant type in most of the world, with the
exception of Japan.

Injection Mould
Main article: Injection mould
Considerable thought is put into the design of moulded parts and their moulds, to
ensure that the parts will not be trapped in the mould, that the moulds can be
completely filled before the molten resin solidifies, to compensate for material
shrinkage, and to minimize imperfections in the parts, which can occur due to
peculiarities of the process.

Injection process: -
Injection Moulding Cycle

Main article: Injection moulding cycle

The basic injection cycle is as follows: Mould close - injection carriage forward
- inject plastic - metering - carriage retract - mould open - eject part(s)

The moulds are closed shut by hydraulics or electric, and the heated plastic is
forced by the pressure of the injection screw to take the shape of the mould.
Some machines are run by electric motors instead of hydraulics or a combination
of both. The water-cooling channels then assist in cooling the mould and the
heated plastic solidifies into the part. Improper cooling can result in distorted
moulding or one that is burnt. The cycle is completed when the mould opens and
the part is ejected with the assistance of ejector pins within the mould.
 Moulding Trial: -
When filling a new or unfamiliar mould for the first time, where shot size for that
mould is unknown, a technician/tool setter usually starts with a small shot weight
and fills gradually until the mould is 95 to 99% full. Once this is achieved a small
amount of holding pressure will be applied and holding time increased until gate
freeze off has occurred, then holding pressure is increased until the parts are free
of sinks and part weight has been achieved. Once the parts are good enough and
have passed any specific criteria, a setting sheet is produced for people to follow
in the future.

Moulding Defects
Main article: Plastic processing troubleshooting
Moulding Alternative
Descriptions Causes
Defects name

Raised or layered Tool or material is too hot, often caused by a

Blister Blistering zone on surface of lack of cooling around the tool or a faulty
the part heater

Air Burn/ Gas Localized burnt zone

Burn Marks (often in the Tool lacks venting, injection speed is too high
Burn yellow/brown tones)

Masterbatch isn't mixing properly, or the

Colour Streaks Localized change of material has run out and it's starting to come
colour through as natural only

Contamination of the material e.g. PP mixed

with ABS, very dangerous if the part is being
Delamination Thin mica like layers used for a safety critical application as the
formed in part wall material has very little strength when
delaminated as the materials cannot bond
Excess material in
Tool damage, too much injection
Flash Burrs
thin layer exceeding speed/material injected normal
part geometry
Foreign particle Particles on the tool surface, contaminated
Embedded Embedded (burnt material or material or foreign debris in the barrel, or too
contaminates Particulates other) embedded in much shear heat burning the material prior to
the part injection

Injection speeds too slow (the plastic has

Directionally "off
cooled down too much during injection,
Flow marks tone" wavy lines or
injection speeds must be set as fast as you
patterns
can get away with at all times)
 Deformed part by
Jetting turbulent flow of Poor tool design
material

Circular pattern
Silver streaks around gate caused
by hot gas

Holding time/pressure too low, cooling

Localized time too low, with sprue less hot runners
depression (In this can also be caused by the gate
Sink Marks thicker zones)
temperature being set too high
Non-Fill /
Short shot Partial part Lack of material, injection speeds too slow Short mould

Splash mark Circular pattern

Splay Marks / Silver around gate
Streaks caused by hot gas

String like remain from

previous shot
Stringiness
Gate hasn't frozen off
transfer in new shot

Lack of holding pressure (holding pressure

Voids Empty space within is used to pack out the part during the
part (Air pocket) holding time)

Discoloured line Mould / material temperatures set too

Weld line Knit Line low where two flow (the material is cold when they meet, so
fronts meet they don't bond)

Cooling is too short, material is too hot,

lack of cooling around the tool, incorrect
Distorted part water temperatures (the parts bow inwards
Warping Twisting towards the cool side of the tool)
Injection moulding is a complex technology with possible
production problems. They can either be caused by
defects in the moulds or more often by part processing
(moulding)
 Stages of Injection moulding

Stage 1

Granulated or powdered thermoplastic plastic is fed from a hopper into the

Injection Moulding machine.

Stage 2

The Injection Moulding machine consists of a hollow steel barrel, containing a

rotating screw (Archemidial Screw). The screw carries the plastic along the
barrel to the mould.

Heaters surround the barrel melt the plastic as it travels along the barrel.

Stage 3

The screw is forced back as the melted plastic collects at the end of the barrel.
Once enough plastic has collected a hydraulic ram pushes the screw forward
injecting the plastic through a sprue into a mould cavity.
The mould is warmed before injecting and the plastic is injected quickly to
prevent it from hardening before the mould is full.

Stage 4

Pressure is maintained for a short time (dwell time) to prevent the material
creeping back during setting (hardening). This prevents shrinkage and hollows,
therefore giving a better-quality product.
The moulding is left to cool before removing (ejected) from the mould. The
moulding takes on the shape of the mould cavity.
The image below shows an Injection Moulding machine

The Injection Moulding-Mould

A mould used for Injection Moulding may cost thousands of pounds to produce
however it does turn out to be economical as many thousands of mouldings
can be produced from a single mould. This results in the low cost of each
moulding.

It used to be the case that when a new type of casting was needed a brandnew
die had to be made. Modern dies and moulds are made from a number of
interchangeable parts. This allows the shape of the mould to be altered.

The dies or moulds used in this process are made from alloy stainless steel.
These special alloy steel moulds are made in a number of parts to allow the
mouldings to be easily removed.

These steel moulds are initially very expensive to make and are suited to
production in quantity where accuracy of size, shape and surface finish is
essential.

Important Features of the Die

It is important that the mould can be easily

opened and the moulding easily ejected. A
slot can often be made along the joint line
of the mould so that a screwdriver can be
inserted and turned to separate the parts.

Deep shapes must be tapered to help

with the removal of the moulding and
ejector pins are usually built into the
mould to push the moulding out.

All moulding cavity surfaces must be

smooth and highly polished to ensure a
good quality of finish to the mouldings.

Sharp corners and sudden changes in

wall thickness should be avoided
because the interrupt the flow of plastic
and weaken the mouldings.

Large flat surfaces should be avoided

because the finished mouldings will often
not come out completely flat.

The image on the right shows the ejector

pins protruding from the one half of the
mould. The moulding has been ejected and
is missing from the image.

Basics of Injection Moulding

Making polymers is a fantastic science. Then there is the matter of shaping
the plastic into useful objects. another fantastic science. One of the most
common methods of shaping plastic resins is a process called injection
moulding. Injection moulding is accomplished by large machines called injection
moulding machines.
 Resin is fed to the machine through the hopper. Colorants are usually fed to the machine directly
after the hopper. The resins enter the injection barrel by gravity though the feed throat. Upon entrance
into the barrel, the resin is heated to the appropriate melting
temperature.

The resin is injected into the mould by a reciprocating screw or a ram

injector. The reciprocating screw apparatus is shown above. The reciprocating
screw offers the advantage of being able to inject a smaller percentage of the
total shot (amount of melted resin in the barrel). The ram injector must
typically inject at least 20% of the total shot while a screw injector can inject as
little as 5% of the total shot. Essentially, the screw injector is better suited for
producing smaller parts.
The mould is the part of the machine that receives the plastic and shapes it
appropriately. The mould is cooled constantly to a temperature that allows the
resin to solidify and be cool to the touch. The mould plates are held together
by hydraulic or mechanical force. The clamping force is defined as the injection
pressure multiplied by the total cavity projected area. Typically, moulds are
overdesigned depending on the resin to be used. Each resin has a calculated
shrinkage value associated with in.

Some Typical Complications

Burned or Scorched Parts: Melt temperature may be too high. Polymer may
be becoming trapped and degrading in the injection nozzle. Cycle time may be
too long allowing the resin to overheat.

Warpage of Parts: Uneven surface temperature of the moulds. Non-uniform

wall thickness of mould design.

Surface Imperfections: Melt temperature may be too high causing resin

decomposition and gas evolution (bubbles). Excessive moisture in the resin.
Low pressure causing incomplete filling of mould.
Incomplete Cavity Filling: Injection stroke may be too small for mould (ie.
not enough resin is being injected). Injection speed may be too slow causing
freezing before mould is filled.

Theory of injection moulding

The theory of injection moulding can be reduced to four simple individual steps:
Plasticizing, Injection, Chilling, and Ejection. Each of those steps is distinct from
the others and correct control of each is essential to the success of the total
process.

• Plasticizing - describes the conversion of the polymer material from its

normal hard granular form at room temperatures, to the liquid
consistency necessary for injection at its correct melt temperature.
• Injection - is the stage during which this melt is introduced into a mould
to completely fill a cavity or cavities.
• Chilling - is the action of removing heat from the melt to convert it from
a liquid consistency back to its original rigid state. As the material cools,
it also shrinks.
• Ejection - is the removal of the cooled, moulded part from the mould
cavity and from any cores or inserts.
The practice of injection moulding

The practice of injection moulding varies from the theory, only in as much as
process limitations and available equipment affect it. Step by step process is
explained in Morgan's Cutting Costs in Short-run Plastic Injection Moulding
guide.

INJECTION MOULDING MACHINES

Hopper
Clamp
Ejectors
Clamp Hydraulics

Barrel

Screw
Injection Hydraulics

Temperature Zones

Mold

Hydraulic
Tank & Pump

Control System

Typical Injection Moulding Machine

Clamping Section: places pressure on the mould allowing highly pressurized

melted plastic material to be injected without separation of the mould
halves.
Gear Train and Motor – used to rotate the screw.

Hydraulic Piston – used to control back pressure on the screw during screw
rotation, and to push the screw forward during inject or mould fill, and to
keep pressure on the plastic which has been injected until it begins to cool
and solidify

CLAMP SYSTEMS:
Injection moulding machines are specified by their clamping force, in tons,
and by their injection capacity, or shot size, in ounces. The clamp on an
injection moulding machine should be capable of opening and closing the
mould as rapidly as possible, and of developing the force required to keep
the mould free from leaking or flashing during injection. It should also have
provisions for protecting damage on the closing stroke, and protecting the
part on the opening stroke.

Three basic types of clamping systems are in use: (1) straight hydraulic,
(2) toggle, and ‘(3) hydraulic mechanical.

• Straight hydraulic clamps have a few but relatively large moving parts. Hydraulic
clamp designs utilize a small hydraulic cylinder to close the clamp at high speed. Just
before the mould halves touch, a prefill valve is closed and high pressure is built up. A
small holding pump maintains this pressure until the clamp opens. Hydraulic clamps
have precise tonnage capabilities, but they are expensive and energy inefficient because
of the necessity of moving large metal components and large volumes of hydraulic oil.
By manipulating the volume and pressure of the hydraulic fluid, the different speeds
and forces required for clamp cycle can be obtained.

Movable Mold Stationary

Hydraulic Tie Bars
Platen Platen
Cylinder
 Straight Hydraulic Clamp

• Toggle or mechanical clamp systems use a small hydraulic cylinder to

actuate the links of a toggle to develop the required force (tonnage).
The mechanical advantage obtained from the toggle geometry allows
high clamping forces to be developed with low hydraulic
requirements. Also, there is a built in slow down at mould closing
and opening. The force generated by the hydraulic cylinder is
increased through the toggle links by multiples of up to 50. Normal
toggle systems require fewer hydraulic controls than the straight
hydraulic system, but the mechanical links and pins are subject to
wear. The toggle system appears to be more common in the small
machine range (under 200 ton) but can be found in up to 700-ton
capacity.

Movable Platen

Stationary Platen
Link Pin

Mold

Hydraulic Cylinder
Tie Bar

Toggle Linkage

Toggle Clamp

• The hydraulic-mechanical combination is the most recent basic clamp

system design. They are designed to take advantage of the good
points of mechanical and hydraulic machines. Some systems use a
basic toggle design, but differ in that clamp tonnage is built by a short
stroke hydraulic cylinder which activates after the toggle links are
fully extended. This reduces the wear on toggle links. Others use
small hydraulic cylinders for traversing the mould, with a mechanical
locking plate to “lock” the mould halves together, and larger, pancake
type, hydraulic cylinders for building the required tonnage.
 Most machines of all three clamp systems designs have low-pressure
mould protection. This prevents damage to the mould if the part
produced in the previous cycle has not cleared the mould before the
clamp closes. The hydraulic pressure moving the clamp is maintained
at a low pressure until the mould halves come together, and if an
obstruction is present between the mould halves, the clamp will stop
and give an indication to the operator that the mould must be cleared.

Setting Machine Process Conditions

Set the melt temperature

2 Set the mould temperature

3 Set the switch-over position

4 Set the screw rotation speed

5 Set the back pressure

6 Set the injection pressure to the machine

maximum

7 Set the holding pressure at 0 MPa

8 Set the mould open time

9 Mould a short-shot series by increasing

injection volume

10 Switch to automatic operation

11 Set the mould opening stroke

12 Set the ejector stroke, start position, and

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ADVANCED INJECTION MOULDING PROCESS

VENTED BARREL TYPE

SCREW COOLING TYPE

HYDRAULIC SYSTEM IN INJECTION

MOULDING MACHINE
HYDRAULIC ACTUATOR ASSEMBLY:

A hydraulic actuator assembly for use in a mould clamping unit of an

injection moulding machine. The actuator assembly serves as a rapid-travel
drive for mould opening and closing movements and as a source of elevated
mould clamping pressure. Among the hydraulic elements contributing to
the operation of the mould clamping unit are a power piston for effecting
elevated mould clamping pressures and a drive piston for effecting rapid
die closing movements. With the hydraulic actuator system of the present
invention, it is possible to control the operation of the mould clamping unit
based on two-sided hydraulic influencing of the power piston and the drive
piston.

HYDRAULIC DRIVE SYSTEM:

A hydraulic or hydrostatic drive system or hydraulic power transmission is
a drive- or transmission system that makes use of a hydraulic fluid under
pressure to drive machinery.

Such a system basically consists of:

• Generator part of the transmission, in general a hydraulic pump, driven by an

electric motor, a combustion engine or a windmill.
• Valves, filters, piping etc. to guide and control the system
• Motor part of the transmission a hydraulic motor or hydraulic cylinder to drive
the machinery.

Hydrostatic means that the energy comes from the flow and the pressure,
but not from the kinetic energy of the flow.

Drive Hydrauli Hydrauli Cylinder Operating

c c
Electric Motor Or Element to

Electric M.E. Hydraulic Hydraulic M.E.

Energy
Energy Energy
Or

HYDRAULICS SYSTEMS
Principle of a hydraulic drive:

Pascal's law is the basis of hydraulic drive systems. As the pressure in the system
is the same, the force that the fluid gives to the surroundings is therefore equal to
pressure x area. In such a way, a small piston feels a small force and a large piston
feels a large force.
The same counts for a hydraulic pump with a small swept volume, that asks for a
small torque, combined with a hydraulic motor with a large swept volume, that
gives a large torque.

NEW CONCEPT OF HYDRAULIC SYSTEM:

Now a day’s electric drive systems using electric servo-motors can be
controlled in an excellent way and can easily compete with rotating
hydraulic drive systems. Hydraulic cylinders are in fact without competition
for linear (high) forces. For these cylinders anyway hydraulic systems will
remain of interest and if such a system is available, it is easy and logical to
use this system also for the rotating drives of the system.

1. Hydraulic servo systems

A high servo control response and a high energy efficiency, which are
difficult to achieve simultaneously, are requested in hydraulic servo systems
of current hydraulic injection moulding machines. This investigation
develops new solutions to concurrently implement energysaving control
and velocity control for simultaneously realising high velocity control
response and high energy efficiency for injection moulding machines. Two
different hydraulic pump systems, including a variable displacement pump
and a variable rotational speed pump, are developed and in each one of
them two different energy-saving control concepts, such as load-sensing
control and constant supply pressure control, are implemented. Thus, for
verifying the feasibility of the integrated control systems and comparing the
energy-saving effects, velocity control of the hydraulic cylinder can be
integrated with four different energy-saving control systems (ESCSs) and
also the conventional hydraulic system without energy-saving control. A
fuzzy sliding mode control that can simplify the complex fuzzy rule bases is
used for solving the complex twoinput two-output systems. The
experimental results show the excellent performance of the integrated
concurrent control systems.

WHAT IS A SERVO?
What is a servo? This is not easily defined nor self-explanatory since a
servomechanism, or servo drive, does not apply to any particular device. It
is a term which applies to a function or a task.
The function, or task, of a servo can be described as follows. A command
signal which is issued from the user's interface panel comes into the servo's
"positioning controller". The positioning controller is the device which stores
information about various jobs or tasks. It has been programmed to
activate the motor/load, i.e. change speed/position.

THE CONCEPT OF A SERVO SYSTEM

The signal then passes into the servo control or "amplifier" section. The
servo control takes this low power level signal and increases, or amplifies,
the power up to appropriate levels to actually result in movement of the
servo motor/load.

These low power level signals must be amplified: Higher voltage levels are
needed to rotate the servo motor at appropriate higher speeds and higher
current levels are required to provide torque to move heavier loads.

This power is supplied to the servo control (amplifier) from the "power
supply" which simply converts AC power into the required DC level. It also
supplies any low-level voltage required for operation of integrated circuits.
As power is applied onto the servo motor, the load begins to move . . .
speed and position changes. As the load moves, so does some other
"device" move? This other "device" is either a tachometer, resolver or
encoder (providing a signal which is "sent back" to the controller). This
"feedback" signal is informing the positioning controller whether the motor
is doing the proper job.
A servo motor is an AC or DC powered motor that uses feedback and
controllers to achieve a specific angular location. Servo motors can achieve
the same levels of accuracy as stepping motors, but must use a closed loop
feedback system whereas stepping motors operate using open loop
systems.

• Can be used under water and Hazardous condition.

• Power is transmitted almost instantaneously. (At a speed of sound
in the hydraulic fluid. Oil incompressible).
• The Hydraulic system will transmit only that amount of fluid energy
called for by the work load. (Electric motor 40% Hydraulic – 10%
or less)
• The parts and mechanism can be located in any place.
• Step less and mechanism can be located in any place.
• Power is transmitted rapidly at a long distance with small loss and
with little slack.
• Automatic control is easily obtained.
• Power/weight ratio is high.
• Motion can be reversed easily.
• Full torque available at all speed.
• Automatic lubrication, less wear and tear, low maintenance
• Speed can be controlled easily.
• Can be stalled without damage.
• Large forces can be applied with no motion.
• It is a comparatively silent system.
• The oil is not subject to damage or breakdown in the same degree
as levers, gears, cams etc.

DISADVANTAGES OF HYDRAULICS SYSTEM:

• Initial cost is high

• Fire hazards
• High creaminess required.
• Skilled personnel required
• The heat energy built up must be removed.

Application of hydraulics:
REFERENCE: -
: CIPET Technical Manual
: Dr. J. A. Brydson
: Dr. J.S Anand
: Berins technical book
: Robins technical book

Internet website: -
: WWW.Google.com
: www.Yahoo.com
: www.msn.com
THANK YOU