4 HYDRAULIC CIRCUIT DIAGRAM & WORKING OF MACHINE

HYDRAULIC CIRCUIT DIAGRAM & WORKING OF

MACHINE

4.1 HYDDRAULIC CIRCUIT DIAGRAM AND WORKING:-

A hydraulic circuit is an arrangement of components such as pumps, actuator,

valves and actuators which are interconnected so as to perform one or more specific
tasks. A hydraulic system is composed of several circuits, and it refers to the complete
assembly of component parts that transmit and control fluid power. A system is
capable of competing one or several operations that constitute a work cycle.

It is very important for the designer to have a working knowledge of components

and how they operate in a circuit. Circuit diagrams are used to design and analyze
both hydraulic circuits and systems. They are constructed from standard graphic
symbols representing components. Hence, it is necessary to know the hydraulic fluid
power symbols. As our machine is divided in two stations, it has a common power
pack which supplies pressurized fluid to different cylinders of both the stations. For
easy understanding we have divided the single hydraulic circuit in two circuits.
Hydraulic circuits of station 1 and station 2are shown in figures.

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 4 HYDRAULIC CIRCUIT DIAGRAM & WORKING OF MACHINE

 STATION 1:

Fig. 4.1 HYDRAULIC CIRCUIT OF STATION 1

 WORKING:
The operator switches on the control button which starts the power
pack actuating motor, pump, 2x2 direction control valve. Then operator will
manually load the tail lamp bracket casting on the locator the job presense
sensor known as laser sensor will sense the existence of component at its
location. The cycle will not start until the laser sesnsor senses the component.
After pressing bi-manual start button, position II of 2x2 DCV will actuate
allowing pressurized fluid to direct in blocked position of all the three 4x3
DCV. Programming of PLC is done in such a way that I position of top

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 4 HYDRAULIC CIRCUIT DIAGRAM & WORKING OF MACHINE

cylinder will actuate allowing the fluid to enter inlet port of cylinder trimming
the top holes of component by forward movement of piston. The top cylinder
will remain in extended position clamping the component on locator. PLC will
actuate solenoid valve SC of right cylinder as soon as proximity sensor senses
the extended limit of top cylinder. This DCV allows the fluid to pass through
flow control valve FCV2 giving controlled fluid flow in inlet port of right
cylinder. A meter in type of flow control is achieved in this process. As the
sensor senses the maximum stoke of same cylinder, position II of DCV will be
actuated allowing controlled flow through FCV5 resulting in retraction of right
cylinder. As soon as right cylinder performs the trimming of rectangular holes,
PLC will actuate I position of drilling cylinder allowing the forward stroke of
it. A dedicated cycle time is given for drilling cylinder to perform drilling
operation. This cylinder performs forward and reverse strokes for 4 times, by
simultaneously actuating I and II position of drilling cylinders DCV. After
completion of drilling operation, solenoid valve SB of top cylinder will
actuate. This makes declamping of component. In this way the cycle of first
station is completed.

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 4 HYDRAULIC CIRCUIT DIAGRAM & WORKING OF MACHINE

 STATION 2:

Fig. 4.2 HYDRAULIC CIRCUIT OF STATION 2

 WORKING:
Then operator will manually load the tail lamp bracket casting on the
locator the job presense sensor known as laser sensor will sense the existence
of component at its location. The cycle will not start until the laser sesnsor
senses the component. After pressing bi-manual start button, position II of 2x2
DCV will actuate allowing pressurized fluid to direct in blocked position of all
the 4x3 DCV. Programming of PLC is done in such a way that I position of

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 4 HYDRAULIC CIRCUIT DIAGRAM & WORKING OF MACHINE

top cylinder will actuate allowing the fluid to enter inlet port of cylinder
trimming the top profile of component by forward movement of piston. The
top cylinder will remain in extended position clamping the component on
locator. PLC will actuate solenoid valve SD of another DCV making position I
to actuate. As the three cylinders are connected by manifold, all the three will
get exetended and retracted at the same time. A controlled forward movement
of LHS, RHS and FRONT cylinder will be achieved. Completion of stroke is
sensed by the sensor making the retraction of all the cylinder. As sson as these
cylinders are retracted, position II of DCV of top cylinder will gets actuated
making the retraction of top cylinder. After completion of the cycle operator
manually unloads the component.

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