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INTRODUTION OF INDUSTRIAL HYDRAULICS, SERVO DRIVES AND PLC

Khelan Mehta
Department of Electronics & Communication Gujarat Technological University V.V.P. Engineering College, Rajkot, 360005, India Email: khelan.mehta@gmail.com

Abstract- In the present paper basic concept of Industrial hydraulics, electric drives and its control are shown which is widely used in automation industries. Different types of pumps, motors and valves used in hydraulics. Here also about electric drives and its control. Electric drives are used to drive the motors and motors are control by a controller or programmable logic controller. By this we can get automatize output and we can direct the robot.

II.

CONFIGURATION AND INTRODUCTION

A) Basic concept and principle of Industrial Hydraulics


Hydraulics is defined as Transmission & control of forces & movements by means of fluids.

Key words- Hydraulic pump, valves, servo drives, PLC.

I.

INTRODUCTION

Today in the era of mass production, the efficient and excellent in quality and fast production (large quantity) is massive. With the use of machines, controlling elements and software we can optimize productivity in the production. During recent years automation can make a large growth in all over world. This can be happen because of countless advantages of it. In automation mainly four types of energy transmission methods but Hydraulics is the best method to transmit the energy. In hydraulics a source of the system is hydraulic pump. It should convert mechanical energy (torque, speed) to hydraulic energy (flow, pressure). The main types of hydraulic pumps which operate on the displacement principle are given below: 1) Gear pump 2) Vane pump 3) Axial piston pump 4) Radial piston pump 5) Screw pump. Every pump has its own advantage. To control the flow we have to use hydraulic valves which are 1) Check valve 2) Direction control valve 3) Pressure relief valve 4) Flow control valve. These all valve are electrically operated (with the use of solenoid). These valves can be control through programmable controller. Hydro pumps are connected with the servo motors which are driven by electric servo drives. It has control unit, input voltage from supply and output voltage to the servo motors. In control unit we have programmable logic controller which is program by a programmer.

Fig. 1 Simple hydraulic circuit

A simple hydraulic circuit is as shown in figure. The whole hydraulics is working on the principle of Pascals Law i.e. P=

Where, P=Pressure A=Area F=Force Transmission of force can be done as shown in the figure 2

Fig. 2 Transmission of flow

Requirement for equilibrium: here A1.A2=cross sectional areas These all things can be done with use of hydrocomponents. Hydraulic pump: The requirement of hydraulic pump is to convert mechanical energy into hydraulic energy. Means mechanical energies like torque and speed can be converted into hydraulic energies which are flow of fluid and pressure. Hydraulic pumps are classified as follows: 1) Fixed displacement pump i) Gear pump ii) Vane pump iii) Axial piston pump iv) Radial piston pump 2) Variable displacement pump i) Vane pump ii) Axial piston pump iii) Radial piston pump 1) External Gear pump: The internal mechanism of gear pump is as shown in fig. 3.

Fig 4 Vane pump

Here vanes are given in the rotor which is act as a piston. This vanes are creates a high pressure to the outlet and we get flow. 3) Axial piston pump: This is most widely used pump in hydraulics. A simple axial piston pump is bent axis pump which is as shown in fig. Here we have to rotate the shaft of pump as shown in fig. this will create suction of one piston and fluid is thrown out from pump by another piston. Suction is defined as blue color and delivered fluid is shown in red color.

Fig 5 Axial piston pump

Fig 3 External gear pump

Axial piston pump with swash plate: In this type of pump, swash plate is used to change the amount of flow. We have to change the angle of the swash plate.

In this pump fluid is drawn through B side and it will come out from side A with the high pressure to get more flow of fluid. 2) Vane pump: In the vane pump internal pressurization is created because casing is of oval shape but rotor is of circular shape as shown in fig. 4.
Fig 6 Axial piston pump with swash plate

In the swash plate highest flow we can get at highest angle. And if plate is parallel then there is lowest flow. This swash plate is controlled by a screw.

4) Radial piston pump: Internal flow of fluid and mechanism is as shown in fig. 7. Here at the center of pump one eccentric shaft is given. As shaft rotating as shown in fig. some fluids are taken in by piston and some are delivering to out late by the piston. The suction port S is given at the bottom of pump and delivery is at top.

3) Flow control valves: It is used to influence the speed of movement of actuators or pistons. Internal architecture is as shown in fig. it can control the flow of fluid.

Fig 7 Radial piston pump

Hydraulic valve: It is used to switching the flow of fluid in hydraulic system. Various types of valves are given as follows, 1) 2) 3) 4) Direction control valves Pressure control valves Flow control valves Check valves 4) Check valve: check valves are used to stop a flow in particular one direction of fluid.

1) Direction control valves: This valve is used to start, stop and change the direction of flow of pressure medium.

2) Pressure relief valves: This valve is used to control the amount of pressure which is generated in the line. We can set this valve to some pressure level and if pressure will goes beyond that value then the valve will open.

Electro hydraulic pump: Now days pumps are replaced by electro hydro pump. This advance pumps having controller in built. We have to program the controller and as per programming a valve is given in pump will operate. And we can control the flow and pressure of fluid as per our requirement. We can also turn on and off the pump for given period of time.

Fig 8 Electro hydro Pump

B) Introduction to servo drives and controls.


As we discuss early about hydraulic pump we need to rotate the shaft. This shaft is rotated with the help of electric motors. In the era of the automation most of all the industries are using the servo motors due to more advantages. The main advantage of servo motor is that it has encoder. Encoder is feedback element. This encoder (Electronic circuit) will help servo to count the distance travelled by motor. This servo motors are driven by the servo drives.

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 ICs. As power is applied onto the servo motor, the load begins to move so speed and position of motor changes. As the load moves, some other

"device" moves. This other "device" is a


tachometer or 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. The positioning controller looks at this feedback signal and determines if the load is being moved properly by the servo motor; and, if not, then the controller makes appropriate corrections. Therefore, a servo involves several devices. It is a system of devices for controlling some item (load). The item (load) which is controlled (regulated) can be controlled in any manner, i.e. position, direction, speed. The speed or position is controlled in relation to a reference (command signal), as long as the proper feedback device (error detection device) is used. The feedback and command signals are compared, and the corrections made. Thus, the definition of a servo system is, that it consists of several devices which control or regulate speed/position of a load. It can be AC or DC servo drives as per requirement for motors.

Fig 8 Servo drives and servo motors

Servo drive is close loop drive with feedback. 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 signal then passes into the servo control or "amplifier" section. The servo control takes this low power level signal and increases, or amplifies the

C) INTRODUCTION TO PLC (Programmable Logic Controller)


A PLC is a user friendly, microcontroller based specialized computer that carried of control of many types and levels of the complexity. It can be programmed, controlled and operate by a person unskilled in operating PC but who is however know the PLC-literate. A PLC will operate any system that has output device that go on and off (known as discrete and digital output). It can operate on both analog and digital input/output devices. Before 1960s in automation industries they are using relay type control panel in control process, it is large and contains lots of wiring, interconnects and relay, which have big maintenance problem. But a typical PLC, which replaces the relay panel and perform the same logic control task. However the PLC is smaller and more reliable. And if any changes occurred in system for PLC its very easy to reprogram.

III.

RESULT AND DISCUSSION

At the end of the introduction of industrial hydraulics, electric drives and controls and PLCs we found that in industrial automation its efficient to use all this type of elements and methods. We can use electric motors in the place of hydraulics, but it has small forces and short strokes w.r.t. hydraulics method. It will also increase the load capacity. As we already discuss that servo drives are more efficient than any others because of inbuilt encoder. And PLCs are more use for controlling in the automation. In automation hydro-pump and electrohydro pump is operated by the servo motors or induction motors. These motors are driven by servo drives and controlled by PLC. PLCs are operating by its own programming software.

Internal block diagram of PLC is as show in fig. it consist of mainly four parts 1) CPU, 2) Programmer/Monitor, 3) I/O Modules, 4) Racks and Chassis. In which CPU consist of microprocessor, memory and power supply. Programmer/monitor is used to communicate with the circuits of PLC. In PLC Input modules allow the electrical signal from external sensor or transducers to the CPU for controlling and output modules are sent the signal to respective relays, solenoids (used in valves), solid state switching devices, motors and display to activate them. The Rack on which the PLC parts are mounted and enclosures where CPU, PM and I/O modules are mounted. Because of nos. of advantages and negligible disadvantages of PLC against relay panels and for more fast and efficient controlling we are using PLCs in all the automation industries.

IV. CONCLUSION After discussion on all about automation we can conclude that in all energy transmission methods hydraulics is the best and easiest method. We have also get knowledge about close loop motors and its drives, a controlling device known as PLC

REFERANCES
1) Hydraulics, Basic Principles and Components by Bosch Rexroth India Ltd. 2) Servo Controls Facts explaining the basics of motion by Baldor motors and drives. 3) Programmable logic controller principle and its application by John W. Webb and Ronald A. Reis.

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