MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
WINTER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Important Instructions to examiners:

1) The answers should be examined by key words and not as word-to-word as given in the
model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try
to assess the understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more
Importance (Not applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the
figure. The figures drawn by candidate and model answer may vary. The examiner may give credit for any
equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant
values may vary and there may be some difference in the candidates answers and model answer.
6) In case of some questions credit may be given by judgment on part of examiner of relevant answer based on
candidates understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.

Q. 1 Attempt the following (Any FIVE): (5 x 4=20)

a) Draw and explain the working of hydraulic system with its general layout (Sketch: 2 Marks,
Explanation: 2 Marks )

Oil hydraulics system uses pressurized oil which is circulated through various components of the
hydraulic system to perform the given task. The various components of hydraulic system have to perform its
intended function and they are arranged to form a layout of the system as per sequence of operation of hydraulic
system. This arrangement of various hydraulic system components as per the nature of equipment/machine is
known as general layout of the system.
The oil from reservoir is cleaned by the filter and sucked by the pump when driven by the motor. The
pump increases the pressure of oil and high pressure oil is then passed through relief valve to drain excess pressure.
Now oil is circulated to the direction to control to the actuator. The oil moves the piston and piston rod to give
output force/motion. This motion/force is then utilized for performing the work/task. The oil from the relief valve
and outlet of the actuator transferred to the reservoir through drain line and recirculated in the hydraulic system.
Figure:

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b) Give classification of Positive displacement pumps (Sketch: 4 Marks)

c) Symbols (4 Marks)

Name Symbols

i) Pressure Compensated flow control valve

ii) Flow divider

iii) Double acting cylinder

iv) 4/2 direction control valve

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d) Telescopic Cylinder (Sketch: 2 Marks, Explanation: 2 Marks)

When numbers of cylinders are arranged in a compact envelope similar to telescope

lenses, it is known as telescopic cylinder. It consists of number of cylinders, with
decreasing in size. The main cylinder accommodates the number of cylinders arranged
one inside the other. The inlet is provided for main cylinder to enter the pressurized oil.
The corresponding inlets are also provided to each cylinder. The cylinders are arranged
in a short envelope hence space required is less.

Working:
When pressurized oil enters in the main cylinder 1 it will push the cylinder 1 in the
upward direction when sufficient oil pressure is generated. Now the cylinder 2 is
completely lifted and oil will enter into the inlet of cylinder 2. The oil will flow in the
cylinder 2 and push the piston in upward direction. It will raise the piston for stroke
length of cylinder 2. In this manner the total length of stroke through which the load is
lifted (L1 + L2)
e) Factors to be considered while selecting the pipe for pneumatic system (Explanation: 4 Marks )
1. Pressure of compressed air in the line.
2. Total flow rate per unit time through the line.
3. Permissible pressure drop in the line
4. Type of tube material and type of line fittings.
5. Length and diameter of tube or other pipelines.
6. Working environment.
f) (Explanation: 4 Marks)
Causes Remedies
i) Excessive heat in oil 1. Check up system pressure and correct it to designed value
2. Check up oil viscosity and replace oil is needed.
3. Inspect the cooling system and set right if found faulty
4. Use proper pipe layout
5. Arrange proper protection from ambient atmosphere
ii) Noisy pump 1. clean filter in inlet line or replace defective filter
2. adjust drive motor to correct rpm if pimp speed is to high
3. check the fluid temperature if oil is too cold, warm-up
4. Pump shaft seal may be damaged. To be replaced.
5. Oil level in reservoir may be down-too upto the specified level.
iii) Low pressure in system 1. Identify the source of leakage and stop leakage
2. May be PRV stuck open pipeline inlet and return line damaged.
3. Set the valves correctly
4. Sources of contamination to be detected and stopped.
5. Defective or damaged accumulator needs to be replaced.

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WINTER 14 EXAMINATION
Subject Code: 12242 Model Answer
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g) Axial Piston pump (Sketch: 2 Marks, Explanation: 2 Marks)

Working: Motor drives the shaft, which in turn rotates the entire cylinder block. The pistons are connected to
inclined swash plate through piston rod. Now since swash plate is inclined and block is rotating, the pistons
reciprocate inside the barrel. The reciprocating motion of piston causes suction and delivery of fluid through inlet
and outlet ports which come in front of outlet of piston.
We can change the angle of swash plate i.e. if
a) = 0 then no flow of oil, because pistons are at same level. When = 0 swash plate is vertical. No
reciprocation of piston, hence no flow.
b) = max or +ve, then x will be stroke length which is maximum and there will be maximum forward flow.
c) = - ve, then x i.e. stroke length will be maximum in reverse direction and hence there will be reverse flow.
By changing the swash plate angle we can vary the stroke length of the piston. and also output flow can be
changed.

2. Attempt the following (Any FOUR) 4 X 4 = 16

a) Gerotor pump: (Sketch: 2 Marks, Explanation: 2 Marks)
It is similar to internal gear pump. But in this pump
crescent is absent. It is dispensed with by using inner gerotor
with one less tooth than outer gerotor. So also the centers
around which both gerotors rotate are at same distance. When
inner gerotor rotates, the pockets go on increasing in size due to
motion. These pockets create suction and oil comes in through
inlet port. On outlet side these pockets area goes on decreasing
and trapped oil is forcefully discharge through the outlet port.
So continuous motion causes continuous discharge.

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b) (Explanation: 4 Marks)

Pressure Relief Valve Pressure Reducing Valve

Function To relive excessive pressure for safety To supply reduced pressure in the
of system certain portion of the circuit

Symbol

Normal Position Normally Closed Normally Open

Operated element Pilot line from input operates the Pilot line from output operates the
poppet sliding spool

c) (Explanation: 4 Marks)

Air Motor Electric Motor Hydraulic Motor

Medium used Compressed air Electric current Pressurised oil

Speed Control Easy using flow control Difficult and costly Easy using flow control valve
valve

Weight/power High Low High

ratio

Efficiency Less High Less

Application Hand tools Electrical equipments Winding/Rewinding reel, feed

drives.

d) Functions of (Explanation: 4 Marks)

1) Oil Seal
a) Prevent both internal and external leakages of fluid
b) Prevent entry of dirt, dust and other contaminants in the system
c) Improve efficiency of the system
d) Maintain oil pressure by maintaining pressure drop due to leakage.

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2) Accumulator
a) To meet peak demand of power
b) To smooth out pressure surges/shocks
c) To provide emergency power source
d) Holding high pressure

3) Heat exchanger
a) Control and maintain fluid operating temperature in a hydraulic system.
b) Prevent the seal from damaging by heat energy

e) Classification of direction control valve (Brief classification: 4

Marks)

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WINTER 14 EXAMINATION
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f) Function of FRL unit (Sketch/Symbol: 2 Marks, Explaination: 2 Marks)

F- Filter
R- Regulator
L- Lubricator
These three units are called service unit or FRL unit. These three units are in bunch and are installed on oneumatic pipe
lines. Compressed air passes through these three units one-by-one
First air enters into F i.e. Filter. In this unit air gets filtered. The micron and submicron particles (very very small like
dust particles) are arrested in filter and gets cleaned.
Filtered compressed sir then enters in to Regulator. This unit regulates the pressure of air required by pneumatic
mechanism or circuit. Suppose the pressure of compressed air is say 8 bar. The circuit demands 3 bar pressure. Then
regulator is used to reduce the pressure from 8 bar to 3 bar. Regulator is a pressure reducing valve.
The regulated pressure air then enters into Lubricator. In lubricator a thin film of oil or very fine oil droplets are
mixed with air. The oil particles are then carried with air to pneumatic circuits and lubricate the components of circuits
(actuators, valves etc) for smooth running and to increase the life of components.

Sketch of FRL unit. (Symbol can also be used)

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WINTER 14 EXAMINATION
Subject Code: 12242 Model Answer
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3. Attempt the following (Any TWO) 2 X 8 = 16
a) Meter-in
Labelled diagram (2 Marks)
Working (1 Marks) When pressurised oil flows through
the circuit it passes through D.C.
valve and enters in the flow control
valve. The opening of the flow
control valve is reduced to decrease
the oil flow rate. Control of piston is
achieved only in advance stroke
Features (1 Marks) Flow control valve F is placed in
pressure line
Advantages (1 Marks) 1. Give best result when used in
higher pressure systems
2. Relatively small friction to face by
piston which increases life of piston
3. Suitable for very low piton rod
speeds.
Meter-out
When oil flow from pump to the
actuator through D.C. valve it will
push the piston in the forward
direction. The oil from the piston rod
side is pushed through the outlet of B
of D.A. Cylinder through the return
line.
Flow control valve F is placed in
return line
1. The actuator movement is very
stable
2. Heat generated due to throttling at
flow control valve is given to the oil
tank.
3. Provides positive speed control of
the cylinder.
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Limitations (1 Marks)
1. No suitable for low pressure system 1. Since both sides of piston there is
pressure., there is possibility of higher
2. Throttling of fluid takes place friction
which heats the oil and hot oil into
admitted into cylinder. 2. Pump works against the maximum
pressure.

Applications (2 Marks)
1. The circuit is used where finer
speed control is required
2. Surface grinders, Welders, Milling
Machines
1. This circuit is used where very
stable movements of actuators are
needed.
2. Drilling, boring, reaming and
tapping operations.

b) Hydraulic circuit for milling machine: (Sketch: 4 marks, Explanation: 4 Marks)

Working: In Hydraulic circuit of milling machine the table
movement of milling machine is required to be adjustable for
different feeds for different type of work. Therefore for both stroke
of cylinder, on both ends of cylinder flow control valves are used.
Another feature of this circuit is that there are two pumps
1. Main pump- low pressure high discharge
2. Booster pump- high pressure low discharge
The function of booster pump is to boost the hydraulic
pressure to higher level than given by main pump. Reason behind
using this type is to save power as well as use of high pressure high
discharge pump is avoided.
4/3 DCV used is mainly operated stroke length of
cylinder is adjustable through limit switch
In center position of 4/3 DCV all the ports are close therefore,
total hydraulic system is lock. In position (I) pump flow is given to
cylinder blank end and extension starts and oil from rod end is
discharge to tank
In (II) position, pump flow diverted to rod end for
retraction and blank end side flow pass to tank

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c) Motion synchronization circuit (Sketch: 4 marks, Explanation: 4 Marks)

Figure shows a synchronizing circuit of two cylinders hooked in parallel by using a flow divider.
The flow divider consists of two fixed displacement, reversible fluid motors of equal volumetric capacity. The
circuit uses fixed displacement pump to supply fluid to two parallel cylinders of equal displacement through a flow
divider. The circuit is controlled by a 4/3 way D.C. valve.

When the D.C. valve is actuated to position (I), the pump fluid is fed to the flow divider which then meters equal
amount of fluid to cylinders 1 and 2, Causing them to extend in synchronization.
When the 4/3 way D.C. valve is in its spring centered neutral position, both the cylinders are locked.
When the 4/3 D.C. valve is actuated to position (II), the pump fluid is then fed to the rod end of each cylinder,
causing them to retract. The return fluid from the blank end of each cylinder is metered in equal amounts in flow
divider to be synchronized.
When the 4/3 way D.C. valve is in its spring centered neutral position, both the cylinders are locked.
When the 4/3 D.C. valve is actuated to position (II), the pump fluid is then fed to the rod end of each cylinder,
causing them to retract. The return fluid from the blank end of each cylinder, before being drained to the reservoir,
is metered in equal amounts through the flow divider, causing the retraction to be synchronized.

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4. Attempt the following (Any TWO) (2 X 8 = 16)

a) Working of sequencing circuit for the two double

acting cylinders: (Circuit diagram 4 Marks)

Working: (working 4 Marks)

Hydraulic cylinders can be operated sequentially using a

sequence valve. Figure shows that two sequence valves
are used to sequence the operation of two double-acting
cylinders. When the DCV is actuated to its right-
envelope mode, the bending cylinder (B) retracts fully
and then the clamp cylinder (A) retracts. This sequence of
cylinder operation is controlled by sequence valves.
This hydraulic circuit can be used in a production
operation such as drilling. Cylinder A is used as a
clamp cylinder and cylinder B as a drill cylinder.
Cylinder A extends and clamps a work piece. Then
cylinder B extends to drive a spindle to drill a hole.
Cylinder B retracts the drill spindle and then cylinder A
retracts to release the work piece for removal.

b) Time delay circuit:

(Explanation 3 Marks)

- Provides a delay between the operation of valve and the movement of actuator.

- When need a time gap between two consecutive operations.

- Time delay valve is main component.

(Sketch 2 marks) (Circuit diagram 2 Marks)

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c) Pneumatic circuit for controlling speed of double acting cylinder

(Circuit diagram: 4 Marks)

Speed control circuit is adopted to control speed

of actuators. This control is achieved by adopting
flow control valve in circuit. In this circuit use 4x 2
DC valve and variable flow control valves. The two
flow control valves are placed in two supply lines of
DA cylinder. As position shown in the circuit
,pressure port P is connected to inlet port A of DA
cylinder. Now we can control the flow of air
admitting in DA cylinder ,through port A, by using
variable flow control valve F1. If more flow will be
allowed then more air will enter in cylinder and
piston will move towards right with more linear
speed, If less air is allowed to flow the linear speed
of piston will be low. When push button is pressed
then pressure port p will be connected to port b of
DA cylinder and exhaust port R will be connected to
port A of DA cylinder .The flow control valve F2
can control the speed of piston .During this stroke
the air from earlier stroke in the other side of piston
will exhausted through flow control valve F1 via
DC valve. During this return the air flow to DC
valve through throttled chamber of flow control valve. Air will not flow through check valve because it is
unidirectional valve. (Explanation 4 Marks)

5 a) i)Muffler One mark each 1 x4

ii)Air Receiver

iii)3/2 DC valve

iv) Shuttle valve

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b) Quick Exhaust Valves :

A quick exhaust valve is a typical shuttle valve.
The quick exhaust valve is used to exhaust the cylinder
air quickly to atmosphere. Schematic diagram of quick
exhaust valve is shown in Figure In many applications
especially with single acting cylinders, it is a common
practice to increase the piston speed during retraction of
the cylinder to save the cycle time. The higher speed of
the piston is possible by reducing the resistance to flow
of the exhausting air during the motion of cylinder. The
resistance can be reduced by expelling the exhausting
air to the atmosphere quickly by using Quick exhaust
valve.
(Sketch 2 marks)
The construction and operation of a quick exhaust valve is shown in Figure. It consist of a movable disc (also
called flexible ring) and three ports namely, Supply port 1, which is connected to the output of the final control
element (Directional control valve). The Output port, 2 of this valve is directly fitted on to the working port of
cylinder. The exhaust port, 3 is left open to the atmosphere.
Forward Motion: During forward movement of piston, compressed air is directly admitted behind the piston
through ports 1 and 2 Port 3 is closed due to the supply pressure acting on the diaphragm. Port 3 is usually provided
with a silencer to minimise the noise due to exhaust.
Return Motion: During return movement of piston, exhaust air from cylinder is directly exhausted to
atmosphere through opening 3 (usually larger and fitted with silencer) .Port 2 is sealed by the diaphragm. Thus
exhaust air is not required to pass through long and narrow passages in the working line and final control valve.
(Explanation 2 Marks)

c) Classification of air compressor: The compressor is selected based on the pressure it needs to operate and the
delivery volume. The compressor can be classified into two main types (1 Mark)
I. Positive displacement compressors and
II. Dynamic displacement compressor

Positive displacement compressors include piston type, vane type, diaphragm type and screw type.
(1 Marks)

(2 Marks)

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d) Classification of air motors: (2 Marks)

i) Gear motor
ii) Vane motor
iii)Gerotar motor
iv)Piston type motor
(Explanation any one of them 1Mark sketch and 1 Mark working)
Gear motor:
Rotary actuators convert energy of pressurized fluid into rotary motion. Rotary
actuators are similar to electric motors but are run on hydraulic or pneumatic
power.
Gear motor
It consists of two inter meshing gears inside a housing with one gear attached to the
drive shaft. Figure shows a schematic diagram of Gear motor. The air enters from
the inlet, causes the rotation of the meshing gear due to difference in the pressure
and produces the torque. The air exists from the exhaust port. Gear motors tend to
leak at low speed, hence are generally used for medium speed applications. Fig.
Vane motor:
A rotary vane motor consists of a rotor with sliding vanes in the slots provided on
the rotor (Fig). The rotor is placed eccentrically with the housing. Air enters from
the inlet port, rotates the rotor and thus torque is produced. Air is then released
from the exhaust port (outlet). Fig.

e) Working of pressure regulator (Sketch 2

marks)

(Explanation 2 Marks)

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f) Shuttle valve: It is also known as a double control valve or

double check valve. A shuttle valve has two inlets and one
outlet. At any one time, flow is shut off in the direction of
whichever inlet is unloaded and is open from the loaded inlet
to the outlet. A shuttle valve may be installed, for example,
when a power unit (cylinder) or control unit (valve) is to be
actuated from two points, which may be remote from one
other.

(Explanation 2 Marks, Sketch 2 marks)

6 a) Advantage of pneumatic system: (3 Marks)

1. -The working medium is air which is easily and freely available.
2. -Sytem is clean
3. -Air cannot be exploded
4. -Easy in working
5. -Maintenance cost is low
6. -Not having return line
Disadvantage of pneumatic system: (1 Marks)
1. -Used upto 10 bar pressure.
2. -The pressure of storage air in tank drops below required pressure.
3. -Accurate motions in actuator are not possible.
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b) Non-return type flow control valve used in pneumatic system: (Explanation 2 Marks)
Pilot operated check valve-A pilot-
operated valve along with its symbol is shown
in Fig. This type of check valve always
permits free flow in one direction but permits
flow in the normally blocked opposite
direction only if the pilot pressure is applied
at the pilot pressure point of the valve. The
check valve poppet has the pilot piston
attached to the threaded poppet stem by a
nut.The light spring holds the poppet seated
in a no-flow condition by pushing against the
pilot piston. The purpose of the separate drain
port is to prevent oil from creating a pressure
build-up at the bottom of the piston. The
dashed line in the graphical symbol represents
the pilot pressure line connected to the pilot
pressure port of the valve. Pilot check valves
are used for locking hydraulic cylinders in position. (Sketch 2 marks any one of them)

c) Push button operated 5/2 DC valve used in pneumatic system: (Sketch 1.5 marks)

Working: 5X2 DC valve is shown in fig. There is single spool. A and B are consumer ports. P is pressure port ,R is
normal exhaust port and S is easy exhaust port.
Port P is connected to port B
Port A is connected to port R
Port S is closed
Now if push button is operated .spring will compress due to movement of spool from left to right and then
Port P is connected to port A
Port B is connected to port S Port R is closed (Working 1.5 marks)

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Symbol (01 mark)

d) Pressure relief valve used in pneumatic system: The pressure relief

valves are used to protect the hydraulic components from excessive
pressure. This is one of the most important components of a hydraulic
system and is essentially required for safe operation of the system. Its
primary function is to limit the system pressure within a specified range. It
is normally a closed type and it opens when the pressure exceeds a
specified maximum value by diverting pump flow back to the tank. The
simplest type valve contains a poppet held in a seat against the spring
force as shown in Figure The fluid enters from the opposite side of the
poppet. When the system pressure exceeds the preset value, the poppet
lifts and the fluid is escaped through the orifice to the storage tank
directly. It reduces the system pressure and as the pressure reduces to
the set limit again the valve closes. This valve does not provide a flat
cut-off pressure limit with flow rate because the spring must be
deflected more when the flow rate is higher. Various types of pressure
control valves are discussed in the following sections: (Working 2 Marks)
Figure - Pressure Relief Valve (2 Marks)

Schematic of direct pressure relief valve is shown in figure 1 This type of valves has two ports; one of which is
connected to the pump and another is connected to the tank. It consists of a spring chamber where poppet is placed
with a spring force. Generally, the spring is adjustable to set the maximum pressure limit of the system. The poppet
is held in position by combined effect of spring force and dead weight of spool. As the pressure exceeds this
combined force, the poppet raises and excess fluid bypassed to the reservoir (tank). The poppet again reseats as the
pressure drops below the pre-set value. A drain is also provided in the control chamber. It sends the fluid collected
due to small leakage to the tank and thereby prevents the failure of the valve.

e) Pressure-Compensated Valves: (Sketch: 2 Marks: Explanation: 2 Marks)

In Pressure-compensated flow-control valves, by changing the size of the orifice in relation to the changes in the
system pressure. This is accomplished through a spring-loaded compensator spool that reduces the size of the
orifice when pressure drop increases. Once the valve is set, the pressure compensator acts to keep the pressure drop
nearly constant. It works on a kind of feedback mechanism from the outlet pressure. This keeps the flow through
the orifice nearly constant re compensated flow control valve used in hydraulic system.

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Schematic diagram of a pressure compensated

flow-control valve is shown in Fig. A pressure-
compensated flow-control valve consists of a main
spool and a compensator spool. The adjustment knob
controls the main spools position, which controls the
orifice size at the outlet. The upstream pressure is
delivered to the valve by the pilot line A. Similarly,
the downstream pressure is ported to the right side of
the compensator spool through the pilot line B. The
compensator spring biases the spool so that it tends
toward the fully open position. If the pressure drop
across the valve increases, that is, the upstream
pressure increases relative to the downstream
pressure, the compensator spool moves to the right
against the force of the spring. This reduces the flow
that in turn reduces the pressure drop and tries to
attain an equilibrium position as far as the flow is
concerned.

In the static condition, the hydraulic forces hold the compensator spool in balance, but the bias spring forces it
to the far right, thus holding the compensator orifice fully open. In the flow condition, any pressure drop less than
the bias spring force does not affect the fully open compensator orifice, but any pressure drop greater than the bias
spring force reduces the compensator orifice. Any change in pressure on either side of the control orifice, without a
corresponding pressure change on the opposite side of the control orifice, moves the compensator spool. Thus, a
fixed differential across the control orifice is maintained at all times. It blocks all flow in excess of the throttle
setting. As a result, flow exceeding the preset amount can be used by other parts of the circuit or return to the tank
via a pressure-relief valve. Performance of flow-control valve is also affected by temperature changes which
changes the viscosity of the fluid. Therefore, often flow-control valves have temperature compensation.

f) Actuator : Hydraulic Actuators, as used in industrial process control, employ hydraulic pressure to drive an
output member. These are used where high speed and large forces are required. The fluid used in hydraulic actuator
is highly incompressible so that pressure applied can be transmitted instantaneously to the member attached to it.
The construction of hydraulic and pneumatic linear actuators is similar. However they differ at their operating
pressure ranges. Typical pressure of hydraulic cylinders is about 100 bar and of pneumatic system is around 10 bar.
(Explanation: 2 Marks)
Classification of actuator in hydraulic system: classified into three types.
1. Linear actuators: These devices convert hydraulic/pneumatic energy into linear motion.
2. Rotary actuators: These devices convert hydraulic/pneumatic energy into rotary motion.
3. Actuators to operate flow control valves: these are used to control the flow and pressure of fluids such as gases,
steam or liquid.
(Types 2 Marks)

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