FACULTY OF ENGINEERING, ARTCHITECTURE & BUILT ENVIRONMENT

Lab Report 1
EK409, Mechatronic Lab VI, Fluid Power & Drives Lab
May - August 2020
Experiment 1: Part 1 Fluid Power Components Identifications.
Part 2 Single Acting Cylinder with 3-Way Valve.

Name ID Course
1) Wong Wei Hao 1001746444 B.Eng (Hons)
2) Wong Wei Herng 1001746821 Mechatronic
3) Gabriel Wong Jung Yit 1001747052 Engineering
4) Choy Melvern 1001746771 (HYEK)
5) How Cheng Yang 1001746720
 TABLE OF CONTENTS

1. Introduction 3

2. Objectives 4

3. Safety Measures and Precautions 5

4. Apparatus and Material 5

5. Methodology 5

6. Results and Discussion 6

7. Conclusion 31

8. Reference 32

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Introduction

Systems that are created to transmit and control power are called power systems. They act as

agents converting energies to kinetic energy in order to move something heavy out of the way or

into a designated location, depending on the purpose. All power systems can be dissembled into

three main components that formed a complete system: the source of energy, usually turbines of

different forms are used to generate mechanical power from other raw energies, transmission,

transformation and regulation of the energy, and the load required to be moved by the system.

There are also three types of power systems, which are mechanical power system,

electrical power system and fluid power system. Mechanical power system is a simpler type of

power system where it does not involve transformation of energy from one form to another,

mechanical energy is generated from the source and is transmitted to the rotary/linear moving

end of the system. A representation of a mechanical system is the drive train of a car, in which an

engine generates mechanical energy from combustion of the fuel, and is controlled by the clutch

to manipulate the different gears rotating, controlling the speed of the car in the end.

The second power system is called electrical power system. They are somewhat similar to

a mechanical power system where they received energy from an input, but instead the energy is

transformed into electrical energy and transmitted to the effector, which is an electric motor at

the end, which allow flexibility, scalability and better effectiveness of the overall transmission

and provides more accurate control of the energy in the system. Lastly, fluid power system is a

type of power system that uses fluid as agents of the energy transmission and transformation.

Depending on the type of fluid used, the fluid power system can be further classified into

pneumatic (compressed air) and hydraulic (liquid) power system. Using the example of the drive

train of the car again, in mechanical power system, the rotating shaft between the clutch and the

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wheels of the car is the agent of transmission of energy, it is the compressed air and liquid in

pneumatic and hydraulic systems respectively. Though hydraulic system can also be further

divided into two groups: hydrostatic power system that makes use of pressurized liquid in

creating motion (A hydraulic jacks and forklifts), and hydrodynamic power system that makes

use of fast-moving liquid.

In this experiment, the students are required to study different fluid power system

components, both pneumatic and hydraulic system, including their parameters and usage in a

system. Then, the students are also required to simulate a single-acting cylinder with 3-way valve

and by manipulating the variables of the components in the systems, the students are to discuss

the result generated and relate it back to real-life application of the system.

Objectives

By the end of this laboratory session, the students will be able to:

- Explain the meaning of fluid power.

- List the various applications of fluid power.

- Differentiate between fluid power and transport systems.

- List the advantages and disadvantages of fluid power.

- Explain the industrial applications of fluid power.

- List the basic components of the fluid power.

- List the basic components of the pneumatic systems.

- Differentiate between electrical, pneumatic, and fluid power systems.

- Appreciate the future of fluid power in Malaysia.

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Safety Measures and Precautions

- Behave in the laboratory by following the regulations, do not eat in the laboratory, do not

run and always wear a suitable attire with lab coats etc.

- Make sure the computers used to conduct the laboratory works are fully functional and

installed with the applications required, such as MATLAB with sufficient features.

- Do not attempt to modify the source codes of MATLAB application.

- Avoid using the counterfeit copy of MATLAB software found on random internet source.

It is illegal and could be sentenced to punishment.

Apparatus and Materials

- MATLAB R2020a, the latest version of the MATLAB software available.

Methodology

1. For the first part of the lab, the components were observed carefully, and their names

were recorded.

2. The uses of the components were researched from sources, such as textbooks and online

websites.

3. For the second part of the lab, a single acting cylinder with 3-way valve model was

created using MATLAB.

4. The, 4 distinctive parameters were manipulated, and the value of cylinder position, valve

position, cylinder pressure and flow through valve were measure.

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Results and Discussion
Part 1: Identifying the Components
Pneumatic Part Part Name Function
Distributor The main function is to
distribute the energy of the
compressed air to the
actuators based on low
power command signal. It
enables the control of the
motion of a rod of the
cylinder or the rotational
motion of a pneumatic
motor.

Pressure gauge It measures the pressure in

order to ensure there are
no leaks or pressure
changes that could affect
the operating condition of
the system.

3/2 way-valve A single acting cylinder

consists of one pneumatic
port to fill and empty the
air chamber, the cylinder
moves in one direction by
filling the chamber or
returns by spring force.
The 3/2 way-valve is used
to fill the air chamber or
vent the chamber to the
atmosphere.

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5/2 way-valve 5/2 way-valve refers to
five ports with two
position valves. It fills
fluid or air into one end of
a double acting device and
allowing the other end
vent to exhaust.

Limit Switch It is used to tally items or

materials when the limit is
reached, the switch closes
or opens.

Throttle Valve It controls the operation

speed of a driving device
and the movement of
machines. It can control
the flow rate of air from
one side to the other side.

Rotary Switch It is used to meter, feed,

and discharge bulk
materials. It controls the
flow of bulk solids under
gravity, pressure, and
vacuum conditions.

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Shuttle Valve Shuttle valve allows fluid
to flow through it from one
of two sources. It can also
allow reverse flow from
the outlet port flows back
through either of the inlet
ports.

Single Acting Cylinder A single acting cylinder

works with compressed air
to actuate the piston in one
direction and it forces to
return to the base position
by the spring.

Air Reservoir Air reservoir act as air

receiver tank which can
store compressed air for
peak demands and allows
air to cool.

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Push Button Switches 0-1 Push button is a switch to
control close or open of an
electro pneumatic circuit
which mainly used for
starting and stopping the
operation of machinery.
‘0’ which in red color is
the stop button while the
‘1’ is the start button.

Dual Pressure valve The dual pressure valve is

switched through when
signals are applied to both
inputs 1. If different
pressures are applied to the
two inputs, then the lower
pressure reaches the output
2.

5/3 Way valve A 5/3-way valve has 1

inlet port, two air cylinder
and two exhaust ports.
Two solenoids control a
valve state. If solenoid is
not energized, the valve
returns to central state and
valve becomes mono-
stable.
Pressure regulator Also known as pressure
reducing valve can
maintain constant pressure
in compressed-air system
either input pressure or
output flow.

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One way valve Also known as check
valve is a valve that
prevent backflow and let
gas flow in one direction.

Stepper Module To ensure a logical

program sequence.

Cylinder, Double Acting Double acting cylinders

can move in both extends
and retract strokes with the
force of air. There are two
ports allow air in which is
outstroke and instroke.
5/2-Way Valve, The functions are almost
Changeover Valve same stated in the 5/2 way-
valve.
It enables the valve to
change over from a series
circuit to a parallel circuit
with a differential-lock
valve.

One-Way Restrictor One-way flow control

valves or one-way
restrictor functions to
control the speed of
flow. The one-way
restrictor valves are
easy to adjust while
high pressure due to
the balance on
structure of design.

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Shuttle Valve It prevents the fluid from
traveling through that
opening, but allows it to
flow through the middle
opening

Power Supply DC The power supply is

24V/6.5A needed to run the circuit.
Without the power supply
the circuit (prototype of
pneumatic trainers) could
not work as there is no
supply to pump/compress
the pneumatic fluids.
Besides that, the DC
Power Supply converts the
AC line voltage into a 24-
V DC voltage that is used
to power the electrical
components of the training
system.
It is protected against
short-circuits.
Conditioning Unit The conditioning unit
limits the pressure of the
air supplied to the
pneumatic circuits. The
Conditioning Unit requires
compressed air from a
central air supply or a
portable unit.

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Distributor Block The function of a
distribution block is to
supply more power
efficiently to a series of
devices. Besides that, the
other function is to isolate
short circuits to prevent
complete shutdown from
occurring.

3/2-Way Valve, Hand- The functions are almost

Operated same stated in the 3/2 way-
valve.
The difference is that it is
operated manually.

Time-Relay, Off-Delay Time-delay relays start or

stop currents from moving
in coils and armatures. It is
designed to allow
electrical circuits to release
at certain times. These
types of relays are
triggered by the signal or
input currents that will
cause a delay.
OFF-delay functions when
the output turns on with
the input and then the
output turns off when the
timer contacts switch after
the set time has expired.
The set time is calculated
from when the input turns
OFF.

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Relay Relay are usually auto
switch that able to open
and close circuits
electromechanically or
electronically. Relays
control the electrical
circuit by opening and
closing contacts in another
circuit. When a relay
contact is normally open,
there is an open contact
when the relay is not
energized
5/2 way-valve normally The functions are almost
closed same stated in the 5/2 way-
valve.
5/2 way is a five port, two
position valve that will put
the flowing mechanism
into one end of a double
acting device as well as
allowing the other end
vent to exhaust.
While on the other side,
normally closed means
that when the valve is not
energized, the supply
pressure port is closed off.

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Part 2: Single-Acting Cylinder with 3-Way Valve

1. Manipulated component: Hydraulic fluid used in the system, and cylinder

The default example of the single-acting cylinder with 3-way valve with their simulation plots:

The default variables in the cylinder and the hydraulic fluid as shown above.

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 Piston and valve positive in every piston stroke in default, unchanged parameter.

The resultant cylinder pressure and fluid flow rate in the default, unchanged system.

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 Piston position to time graph as projected in the Simscape Result Explorer (Similar to the first

graph projected above)

2. Then, the resultant piston and valve position, cylinder pressure and flow through valve will be

recorded when the following variables are being manipulated:

a) Hydraulic Fluid (From Skydrol LD-4 to Water)

With only the change of hydraulic fluid in the system, it is expected to affect the overall pressure

of the system and the flow through the valve but remain unchanged in the piston and valve

location, due to the difference in fluid density (Water > Skydrol LD-4, meaning water is heavier

at the same volume, requesting more power to pump the same amount of fluid) and viscosity

(Skydrol LD-4 > Water, meaning the fluidity of Skydrol is lower, but it lower the internal

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leakage and provide better viscosity index). This is further shown in the simulated result as

tabulated:

Paramete Original System (Skydrol LD-4) New System (Water)

Piston

Position

(m)

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Valve

Position

(m)

Discussion: The change in hydraulic fluid has no effect on piston and valve position at all, this

is obvious because the piston and valve movement are affected by the parameters of the pump

and valve opening, instead of hydraulic fluid. The slight deviation in the data shown above are

the calculation/rounding-off error from the simulation which can be neglected.

Cylinder

Pressure

(Pa)

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Flow

rate

(m3/s)

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Discussion: The system filled with Skydrol LD-4 has a smaller mean (absolute average)

cylinder pressure (around 1kPa lower) than the system driven by water, as assumed above.

This is because the density of Skydrol LD-4 is lower than water and lesser pressure is

generated while the pump pushes the fluid out of the piston as compared with water. Similar

result can be obtained by measuring the flow through valve, where Skydrol LD-4 is slightly

higher than water, even with higher viscosity, due to the lower density.

In other words, Skydrol LD-4 is a better hydraulic fluid especially in carrying heavy loads, as

it is more efficient than water in the system and its high viscosity makes it a great lubricating

agent and minimizes internal leakage and increasing the pump efficiency. Thus, Skydrol LD-4

is favored in aviation usage where it acts as the hydraulic fluid in airplane landing gear and

lubricants in various plane models.

b) Piston Area (From 0.002m2 to 0.001m2)

Paramete Original System (0.002m2) New System (0.001m2)

Piston

Position

(m)

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Valve

Position

(m)

Discussion: As the piston area decreased, the volume of the cylinder decreased as well.

Considering the dead volume (clearance volume or air space that the piston cannot close on) in

the default cylinder is 0.000006m3 , the displacement volume of the cylinder is further reduced

and resulted in the decrease in piston peak position (shorter length overall), and reaches the

peak piston position faster. And due to the halved volume in the piston, this resulted in the

valve position to be slightly lower as well, due to the decreased flow through valve.

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Cylinder

Pressure

(Pa)

22
Flow rate

(m3/s)

Discussion: With the reduced piston area, the volume of the cylinder decreased, and the

pressure exerted by the fluid as the piston pump out of the cylinder decreased as well as lower

volume of fluid entered the cylinder. This can be observed with the mean and median value of

the cylinder pressure. With lower volume in the cylinder, this resulted in lower flow rate

through valve as well.

c) System Temperature (40 degree Celsius to 100 degree Celsius)

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The results are as below (All other parameters are default with hydraulic fluid being Skydrol LD-

4):

Paramete Original System (40 degree Celsius) New System (100 degree Celsius)

Piston

Position

(m)

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Valve

Position

(m)

Discussion: The change in system temperature has no effect on piston and valve position at all,

this is obvious because the piston and valve movement are affected by the parameters of the

pump and valve opening, instead of overall system temperature. The slight deviation in the

data shown above are the calculation/rounding-off error from the simulation which can be

neglected.

Cylinder

Pressure

(Pa)

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Flow rate

(m3/s)

Discussion: As opposed to general assumption of the higher the system temperature, the higher

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the pressure within the system, the result has shown that the higher temperature Skydrol LD-4

has resulted in lower pressured cylinder and also higher flow rate. To explain this, do bear in

mind that the flash point (boiling point) of Skydrol LD-4 is around 180 degree Celsius, which

mean, it is still in liquid state at 100 degree Celsius, but the high temperature does make the

fluid expand, and making it less denser than it was at 40 degree Celsius. This explained why

the mean cylinder pressure is lower when the system temperature is 100 degree Celsius, as the

lower density fluid is lower in weight at the same amount and required lesser force to push the

fluid out of the cylinder, thus a lower cylinder pressure is recorded. Also, as the fluid has

expanded, the volume flowing through the valve is increased and result in higher flow rate too.

This is observed in the Flow Through Valve plot as above. However, it is proven by sources

that the flow rate of the system is only affected by temperature with square-root factor, which

means that temperature has only little effect on the overall flow rate.

d) Piston Stroke (From 0.25m to 0.1m)

Paramete Original System (0.25m) New System (0.1m)

Piston

Position

(m)

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Valve

Position

(m)

Discussion: With shorter piston stroke in the cylinder, the piston reached the peak position

much faster and oscillated all the way back to the bottom space. And with that the fluid

compressed more in the cylinder, thus it flowed through the valve much stronger and an much

higher valve position is observed, almost doubled of the original reading.

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Cylinder

Pressure

(Pa)

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Flow rate

(m3/s)

Discussion: As the stroke is shorter, the peak piston position is reached faster and the pressure

surged a lot higher when the piston reached the peak position. However, it damped down

instantly and remained constant due to the short stroke. The similar situation can be observed

in flow rate through valve, reached the peak a lot quicker and dampened down almost instantly

after the surge.

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Conclusion

By the end of this experiment, the students have gotten their more in-depth experience with the

fluid power components and understanding their usage, and also utilizing MATLAB application

to simulate the fluid power system and learning the working mechanism by manipulating the

parameters. This required more attention and effort to be invested to fully understand the steps

and procedures as this simulates the real-life application of MATLAB in fluid power industrial

usage. Thus, it is safe to say that the students had obtained the basic skillset required in running

simulations and utilizing the software to create bigger systems.

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Reference

1. Esposito, A. (2008). Fluid Power with Applications. (7th Edition). Pearson.

2. Durfee, W., Sun, Zongxuan., Van de Ven, J. (2015). Fluid Power System Dynamics.

(Revised Edition). Center for Compact and Efficient Fluid Power, University of

Minnesota.

3. Daines, JR. (2012). Fluid Power: Hydraulics and Pneumatics. (2nd Edition). Goodheart-

Willcox.

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