Hydraulic cylinders are used in many types of machines and systems for industrial and mobile applications. The manufacturing process of cylinders mainly involves the following steps: design, heat treatment, machining, coating, assembly, and testing. The Design Phase, Cylinder Manufacturing In the design stage, the requirement specifications of the cylinder to be designed are transformed into […]
In every hydraulic system, a tightly confined incompressible fluid medium is used to transmit energy from the power pack to the actuators in the system. The fluid medium is formulated from a base stock and additives. The base stock should possess all the essential characteristics to perform well in a particular class of hydraulic systems. […]
This article is the third part of the following three-part series of articles: Filtration and Drying Principles in Pneumatic Systems Filtration Principles in Hydraulic Systems Filtration Principles of Pneumatic and Hydraulic Systems: A Comparison Study The filtration principles of pneumatic and hydraulic systems were given in the previous articles. The third part of the three-part […]
This article is the second part of the following three-part series of articles: Filtration and Drying Principles in Pneumatic Systems Filtration Principles in Hydraulic Systems Filtration Principles of Pneumatic and Hydraulic Systems: A Comparison Study A hydraulic power system transmits the power in a controlled manner using an incompressible oil medium. Remember, the fluid medium […]
This article is the first part of the following three-part series of articles on filtration: 1. Filtration and Drying Principles in Pneumatic Systems 2. Filtration Principles in Hydraulic Systems 3. Filtration Principles of Pneumatic and Hydraulic Systems: A Comparison Study A pneumatic power system transmits the power in a controlled manner using a compressed air […]
The natural water vapor content of air is concentrated and is carried through the compression process in a compressor as a vapor in high temperatures. A proper means of dehydration must be incorporated in the conditioning of compressed air where demands of high quality compressed air are entailed. A dryer can be used to receive […]
This article can be downloaded by clicking the link here A bladder accumulator consists of a seamless cylindrical pressure vessel (shell), internal elastomeric bladder, poppet valve, fluid (oil) port, charging valve, and clamps and brackets. A schematic diagram of a bladder accumulator is shown in the figure below and the basic constructional features and specification […]
[This is an extract of the article on ‘Mounting Configurations of 4-port Hydraulic Directional Control Valves’ authored by Joji Parambath. Full article can be downloaded by clicking the link here] Table 1 presents the size designations, port sizes, and nominal flow rates for different sizes of 4-port hydraulic directional control valves according to the DIN […]
Hydraulic cylinders are designed to operate at high pressures and handle high loads in demanding operating conditions. Therefore, they need to be constructed with materials of high strength, expert workmanship, and advanced features to provide ruggedness, high quality, maintenance-free operation, and long service life. Some of the features of cylinder construction are presented below to […]
A long-stroke hydraulic cylinder often experiences significant side-load forces while in operation, especially when it is fully extended. The side load in the cylinder is the force component that acts laterally across the axis of its bearings, piston-rod seals, or piston. Many reasons can be attributed to the development of side loads on the cylinder. […]
The preventive maintenance is carried out on hydraulic systems to keep them in a perfect working condition at all times. However, faults or breakdowns do occur in hydraulic systems, which have to be traced and corrected with minimum delay and expense. Table below gives pump malfunctions and their potential causes and rectification. Disturbances Possible causes […]
Some essential precautions necessary for the safe operation of hydraulic systems are enlisted below: Design and build hydraulic systems with safety in mind, Select hydraulic components and fluid conductors that are rated for the highest system working pressure, Position valves, safety guards, and controls with the operator’s safety in mind, Know the hazards involved in […]
Most of the hydraulic system failures are similar. That is there is a sudden or gradual loss of pressure or flow. Consequently, cylinders and motors in these systems may stop working. Any of the system components can be at fault. Possible causes of hydraulic cylinder faults and their rectification are highlighted below: Possible causes Rectification […]
Any hydraulic system is inherently dangerous, as an enormous amount of energy is transmitted through the high-pressure system. There are many hazards associated with hydraulic systems. The safety of personnel must be ensured while they are operating and maintaining hydraulic systems. Every operator of hydraulic systems has the right to know the hazards of his/her […]
In two-hand safety operations in dangerous industrial operations, such as a pneumatic press, the hands of an operator must be engaged for safety reasons. This condition is usually achieved by arranging two pushbuttons (Say, PB1 and PB2) arranged at a distance. That means, the operator cannot press the pushbuttons with one hand. At times, there […]
A PLC system is usually designed with LEDs on the CPU, power supply, and I/O modules for fault diagnosis. It is usually provided with built-in fault analysis measures to carry out self-testing and display fault codes, which can then be interpreted by looking up the code in a list provided by the manufacturer to give […]
A PLC system is configured using several networked components, such as PLCs, computer, communication modules, and HMI, with communication interfacing capabilities. These components can exchange data between two or more communication partners through the network using specific protocols for handling the data traffic. A network is characterized by the type of hardware involved, communication procedure, […]
Discrete output proximity sensors are most important for industrial applications. They gain importance in such applications where it is necessary to record or count moving objects or work-pieces on machines or conveyors. Based on the way of connection of the final output amplifier transistor of a discrete proximity sensor to the power supply terminals, proximity […]
As you are aware, a pneumatic system is an interconnection of various components such a compressor, actuators, control valves, and other elements using fluid conductors. The operation of the pneumatic system is affected by the presence of heat, dust, moisture, leaks, loose bolts, and misalignment in the system. Lack of regular maintenance may result in […]
Seals (or packings) are deformable materials sandwiched between the mating surfaces to close of their small gaps. They retain fluid under pressure within the system and keep foreign matter out. They prevent the metal-to-metal contact of sliding surfaces. They are made from polymer materials that are flexible (rubber) and soft (plastics). The elastomeric quality enables […]
An electro-pneumatic system, in general, consists of an electrical or electronic control part controlling the pneumatic power part of the system. Integrating the power density of pneumatic systems with the controlling possibilities of the electric systems opens up a new world of opportunities for the high-performing pneumatic systems. In this hybrid technology, solenoid valves are […]
The cleanliness of hydraulic fluids needs to be monitored for maintaining the components of hydraulic systems at a satisfactory level. Many national and international organizations such as ISO, SAE, National Aerospace Standards (NAS), etc., have developed standards for specifying the particle size classification and contamination concentration levels in hydraulic fluids. All standards specify the contamination […]
The primary goal while designing a hydraulic system is to use less energy and do more work. A conventional hydraulic system with a fixed-displacement pump provides a constant flow through the system. The maximum system pressure is limited by the settings of a pressure relief valve in the system. When the load demands less flow […]
The most common valve configurations used for hydraulic control systems range from the discrete valves controlled by the electromagnets to infinitely variable valves, controlled by the special proportional electromagnets (or torque motors). Proportional valves are devices for obtaining the finely variable flow and pressure controls using proportional electromagnets. They were developed as a low-cost alternative […]
Design of Industrial Hydraulic Systems in the SI Units By Joji Parambath The book describes the design aspects of hydraulic systems systematically. It highlights the essential parameters and specifications of hydraulic components in SI units. Design Concepts in Industrial Hydraulic Systems in the English Units By Joji Parambath The book highlights the essential parameters and […]
Hydraulic Pipes Tubes and Hoses in the SI Units By Joji Parambath This book presents the necessary information about the configuration, performance specifications, and other details of pipes, tubing, and hoses and their fittings. The book uses the SI system of units. Pipes Tubes and Hoses in Hydraulic Systems in the English Units By Joji […]
Hydraulic Cylinders in the SI Units By Joji Parambath This book deals with hydraulic cylinders of varying designs. The principles of operation, constructional details, and classification of the hydraulic cylinders are explained in detail. This chapter also covers the topics on the position transducers, swing clamp cylinders, applications, design aspects of hydraulic cylinders, advantages, and […]
Hydraulic Power Packs in the SI Units By Joji Parambath The book deals with power pack components such as hydraulic reservoirs, pumps, pressure relief valves, unloading valves, filters, accumulators, and power pack control units. It also presents the noise reduction techniques for hydraulic systems. Next, the book highlights power packs with standardized assemblies. The book […]
Textbook on ‘Hydraulic Filters Construction Installation Locations and Specifications’ By Joji Parambath The textbook presents information on the construction, installation locations, and specifications of hydraulic filters, in detail. Please click on the image links to go to the Amazon Website Hydraulic filters need to be the integral parts of every hydraulic system to ensure the […]
Textbook on ‘Maintenance Troubleshooting and Safety in Pneumatic Systems By Joji Parambath The book highlights all aspects of maintenance, troubleshooting, and safety in pneumatic systems, systematically. A section on energy saving highlights the steps that need to be taken for saving a substantial amount on energy costs. Textbook on ‘Maintenance, Troubleshooting and Safety in Hydraulic […]
Textbook on ‘Design of Pneumatic Systems in the SI Units’ By Joji Parambath The book explains the design aspects of pneumatic systems systematically. The book also presents many typical examples of designing pneumatic systems using the SI units. Textbook on ‘Design Concepts in Pneumatic Systems in the English Units Please click on the image links […]
Electro-pneumatics and Automation Authored by Joji Parambath This book explains the functioning of single and double solenoid valves and various electrical control components such as pushbuttons, electro-magnetic releys, limit switches, reed switches, proximity sensors, timers, preset counters, and pressure switches. Many typical single-actuator and complex multiple-actuator electro-pneumatic circuits are also developed to illustrate various applications […]
Textbook on ‘Pneumatic Systems and Circuits -Basic Level in the SI Units’ By Joji Parambath The book describes the topics on compressed air generation and contamination control, pneumatic actuators, and control valves, in detail. Many single-actuator control circuits are presented. Further, the book presents the maintenance, troubleshooting, and safety aspects of pneumatic systems. The book […]
Different positions of a group-changing pneumatic circuit for four cascade groups used for eliminating signal conflicts are illustrated in Figure below. Three pilot-operated 5/2 DC valves (reversing valves) are used to realize the group changing circuit. Figure | Different power supply positions of a four-group circuit Initially, the supply is in the last group, G4, […]
Some essential factors concerned about the operation of hydraulic pressure regulators are its set pressure, cracking pressure, full-flow pressure, pressure-override, closing pressure, overpressure, blowdown, and backpressure. These useful terms are defined in the following sections: Set Pressure It is the inlet pressure, under the specified service conditions, at which a PRV is set to open. […]
Industrial Hydraulic Systems and Circuits Basic Level in the SI Units By Joji Parambath The textbook deals with the components and circuits of hydraulic systems. The fundamentals required to understand the core topics are given initially. The book describes the topics on power packs, hydraulic actuators, and control valves, in detail. Next, the book also […]
Some critical factors relevant to the operation and applications every hydraulic motor are its operating pressure, displacement, flow rate, input power, output power, torque output, and efficienOperating Pressure (P) It is the pressure in a hydraulic system that overcomes all resistances in the system, which includes both useful work and losses. The rated pressure of […]
A multi-stage telescopic cylinder has many cylinder bodies inside one another. That is; the piston-rod of the first stage is used as the barrel of the second stage, and the second piston-rod is used inside the barrel of the second stage. Similarly, there can be up to six stages in the cylinder. Therefore, the total […]
Textbook on ‘Hydraulic Accumulators and Circuits in the SI Units’ By Joji Parambath The textbook presents information on the classification, constructional features, working, and essential terms and definitions, sizing, and safety and maintenance aspects of hydraulic accumulators. The book uses the SI system of units. Textbook on ‘Accumulators in Hydraulic Systems in the English Units’ […]
Pneumatic Systems and Circuits -Basic Level (in the SI Units) By Joji Parambath The book describes the topics on compressed air generation and contamination control, pneumatic actuators, and control valves, in detail. Many single-actuator control circuits are presented. Further, the book presents the maintenance, troubleshooting, and safety aspects of pneumatic systems. The book uses units […]
The work process to carry out an industrial task usually involves many recurring steps. These steps can be carried out manually or automatically. In the manual system, an operator is always present to decide every process step. In the automatic system, the process controls itself, partially or entirely, by the feedback of its condition. Therefore, […]
The compression (or expansion) of air can be thought of as taking place under isothermal or adiabatic or polytropic conditions. Isothermal compression process takes place under constant temperature condition. When a volume of air in a system is compressed or expanded instantly, there is no time to add or dissipate heat into or out of […]
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