Fakulti:

FAKULTI KEJURUTERAAN ELEKTRIK

Nama Matapelajaran: MAKMAL KEJ. ELEKTRIK

Kod Matapelajaran : SKEM 3742

Semakan
Tarikh Keluaran
Pindaan Terakhir
No. Prosedur

:2
: 2013
: 2015
:

SKEM3742
FAKULTIKEJURUTERAANELEKTRIK
UNIVERSITITEKNOLOGIMALAYSIA
KAMPUSSKUDAI
JOHOR
MECHATRONICSLABORATORY

ELECTROHYDRAULIC&
ELECTROPNEUMATIC
Disediakan oleh
Nama

: Dr. Salinda Buyamin

: Ir. Dr. Kumeresan
En. Mohd Ariffanan
Mohd Basri
PM Dr. Rosbi Mamat

Disahkan oleh : Ketua Jabatan

Nama
: PM Dr. Zaharuddin Bin
Mohamed

1. THEORY
i.

Definition

Electro-hydraulic (electro-pneumatic) term is defined from words of electro, which mean electrical
and hydraulic (pneumatic) which mean hydro/liquid (air) pressure. The electro-hydraulic (electropneumatic) equipment and system is an integration of electrical and mechanical components with
compressed liquid (air) source.
ii.

Components

Electro-hydraulic (electro-pneumatic) controllers have a hydraulic (pneumatic) power section. In an

electro-hydraulic (electro-pneumatic) control, the signal control section is made up of electrical
components, for example, the proximity switches, and relays. The directional control valves
behaves as a medium between the electrical signal control section and the hydraulic (pneumatic)
power section in the controller (refer Figure 1.1).

Command
execution

Signal
output

Signal
processing

Signal
input

Signal flow

Power components
- Cylinder
- Optical displays

Hydraulic/
pneumatic
power section

Final Control Elements

- Electro hydraulically/
pneumatically operated
directional control valves
Processing Elements
- Relays
- Contactors
Input Elements
- Pushbuttons
- Limit switches
- Reed switches
- Ind. proximity sensors
- Cap. proximity switches

Electrical signal
control section

Electro-hydraulic/electro-pneumatic
Components

Figure 1.1: Signal flow and components of an electro-hydraulic/electro-pneumatic control

system

~End~

iii.

Switch

There are 3 types of electrical switches used in the design of electro-hydraulic (electro-pneumatic)
circuit. They are:
i)
Normally-opened (NO) contact switch (refer Figure 1.2(a)).
ii)
Normally-closed (NC) contact switch (refer Figure 1.2(b)).
iii)
Changeover contact switch (refer Figure 1.2(c)).

Figure 1.2(a): Normally-opened contact switches

Figure 1.2(b): Normally-closed contact switches

Figure 1.2(c): Changeover contact switches

~End~

iv.

Relay

Relay is an electrical device that contains a coil and a contactor switch. Relay also can consist of a
coil and multiple contactors. Figure 1.3 shows a coil (K) with 4 contactor switches. If the coil is
activated, the Changeover Contact will change its state. A NO switch will change its state from ON
to OFF state.

Figure 1.3: Relay with a coil and multiple contactor switches

v.

Solenoid Valve

Solenoid valve is an electro-mechanical device that built-in with a coil (solenoid) and a
hydraulic/pneumatic directional control valve (DCV). There are many types of built-in solenoid
directional control valve. A few of them are:

4/2 Way DCV single solenoid with spring return

4/3 Way DCV double solenoid with spring return
2/2 Way DCV single solenoid with spring return
5/2 Way DCV double solenoid

a. Basic Electro-Hydraulic Operation Using the 4/2 Way DCV Single Solenoid
The 4/2 way DCV single solenoid or monostable valve consists of a built-in solenoid at the left hand
side and a built-in spring at the right hand side of the valve. Figure 1.4 shows the hydraulic and
electrical circuits (electro-hydraulic circuits) for actuating a double acting cylinder using 4/2 DCV
single solenoid.
When pushbutton S1 is pressed, coil R1 is activated. Activation of R1 will turn ON the NO
K1switch. Once, K1 is ON, it will activate Y1. Solenoid Y1 will change the position of the valve
from the original position (right dominant) to the new position (left dominant). The liquid will start to
flow into the left side of the cylinder. This will cause the rod of the cylinder to extend.

~End~

Figure 1.4: 4/2 DCV single solenoid is used for actuating a double acting cylinder
b. Basic Electro-Hydraulic Operation Using the 4/3 Way DCV Double Solenoid
The 4/3 Way DCV double solenoids consists of two solenoids (Y1 and Y2) at the both sides of the
valve. It is also called bistable valve or memory valve. Basically, the 4/3 Way DCV are identical
with 4/2 way DCV. The difference is that a center section is added for 4/3 DCV. Figure 1.5 shows
the hydraulic and electrical circuits (electro-hydraulic circuits) for actuating a double acting cylinder
using 4/3 DCV single solenoid. Initially, the 4/3 DCV single solenoid is at a stable state (center
dominant).
When pushbutton S1 is pressed, coil R1 will be activated. Activation of R1 will turn ON the NO K1
switch. Once, K1 is ON, it will leads to activation of solenoid Y1. Solenoid Y1 will change the
position of the valve from the original position (center dominant) to the new position (left dominant).
On the other hand, if pushbutton S2 is pressed, coil R2 will be activated. Activation of R2 will turn
ON the NO K2 switch. Once, K2 is ON, it will lead to activation of solenoid Y2. Solenoid Y2 will
push the position of the valve from the original position (center dominant) to the new position (right
dominant).

Figure 1.5: 4/3 DCV double solenoid is used for actuating a double acting cylinder
~End~

c. Basic Electro-Pneumatic Operation Using 2/2 Way DCV Single Solenoid

The 2/2 way DCV single solenoid or monostable valve consists of a built-in solenoid at the left hand
side and a built-in spring at the right hand side of the valve. It is used to control the actuation of
double acting cylinder.
Figure 1.6 shows the electro-pneumatic circuit for actuating a single acting cylinder using 2/2 DCV
single solenoid. When pushbutton S1 is pressed, coil R1 is activated. Activation of R1 will turn ON
the NO K1 switch. Once K1 is ON, it will leads to activation of solenoid Y1. Solenoid Y1 will
change the position of the valve from the original position (right dominant) to the new position (left
dominant). The air will start to flow into the left side of the cylinder. This will cause the rod of the
cylinder to extend.

Figure 1.6: Electro-pneumatic circuit for actuating a single acting cylinder

d. Basic Electro-Pneumatic Operation Using 5/2 Way DCV Double Solenoid

The 5/2 way DCV double solenoid consists of two solenoids (Y1 and Y2) at both sides of the valve.
It is also called bistable valve or memory valve. The 5/2 way DCV is used to control the actuation
of double acting cylinder. Figure 1.7 shows the electro-pneumatic circuit for actuating a double
acting cylinder using the 5/2 DCV double solenoids.
Initially, the 5/2 DCV double solenoid is at the initial state (right dominant). When pushbutton S1 is
pressed, coil R1 is activated. Activation of R1 will turn ON the NO K1 switch. Once K1 is ON, it
will leads to activation of solenoid Y1. Solenoid Y1 will change the position of the valve from the
original position (right dominant) to the new position (left dominant). The air will start to flow into
the left side of the cylinder. This will cause the rod of the cylinder to extend.
Then, if the pushbutton S1 is released and the pushbutton S2 is pressed, coil R2 is activated.
Activation of R2 will turn ON the NO K2 switch. Once, K2 is ON, it will lead to activation of
solenoid Y2. Solenoid Y2 will push the position of the valve from the current position (left dominant)
to the new position (right dominant). The air will start to flow into the right side of the cylinder. This
will cause the rod of the cylinder to retract.

~End~

Figure 1.7: 5/2 DCV double solenoid is used for actuating a double acting cylinder
vi.

Proximity Sensor

Proximity sensors, Figure 1.8, are commonly used to monitor a process condition in a machine. For
instance, sensor is used to ensure the raw part was placed on a fixture, height of raw material within
control, etc. There are three types of proximity sensors:

Inductive sensor able to detect metal, especially mild steel

Capacitive sensor able to detect most parts except low-density product
Optical sensor able to detect bright surface reflectively except black / rough surface

Figure 1.8: Proximity sensor (PS) is placed at the beginning of the actuator movement

~End~

a. Operation of the self-holding (memory) electrical circuit for Electro-Hydraulic and

Electro Pneumatic
The self-holding electrical circuit is as shown in Figure 1.9. The function of this circuit is to
provide continuous electrical signal to the circuit even after the pushbutton S1 is released.

S0

+24V

S1

K1

S2

0V

K1

Figure 1.9: The self-holding electrical circuit

It is made up of:
1. A NO detent switch, S0.
2. A NO pushbutton, S1.
3. A NC pushbutton, S2.
4. A relay, K1 (with a NO changeover contact switch K1).
The operation of the self-holding circuit is as follows: when the pushbutton S1 is pressed for a
short period of time, the coil of relay K1 is activated. The (changeover contact) switch K1 closes
and relay K1 remains activated even after the pushbutton, S1 is released. Pushbutton S2 is pressed
to cancel the self-holding effect. Detent switch S0 is use as a safety switch.

~End~

2.

TASKS

2.1. Electro-Hydraulic
Task 1: Actuation of the 4/2 Way Directional Control Valve.
Practice Objective
After working through this practice, students are expected to be able to understand the basic
operation of the electro-hydraulic control circuits using a double-acting cylinder.
Procedure
1. Connect the hydraulic circuit according to Figure 2.1(a).
2. Connect the electric circuit as shown in Figure 2.1(b).
3. Validate the hydraulic circuit and the electric circuit for any misconnection.
4. Turn the hydraulic power unit ON. Adjust the pressure to 25 to 35 MPa at the
pressure- limiting valve.
5. Turn the DC Power Supply ON. Set the voltage to be 24V.
6. Turn S0 ON.
7. Press and hold S1, verify if the piston rod continue to extend to its maximum limit.
8. Release S1; verify if the piston rod retracts.
9. Once you finish the practice, turn OFF of the Hydraulic Power Unit and DC Power
Supply.
S0
1

+24V

3
3

S1

K1

B
A

Y1

K1

Y1

T
P

0V

Ts

(a)Hydrauliccircuit

(b)Electricalcircuit

Figure 2.1: Circuit drawing of hydraulic and electrical circuits for Task 1
Assignment:
Based on your observation, fill in Table 2.1.
Table 2.1
Double-Acting Cylinder (Extend/Retract)

S1
Pressed
Released
Based on your understanding, describes the expected result if the connection A and B to cylinder is
swapped.
~End~

Task 2: Self-holding (Memory) Electro-Hydraulic Circuit Using Relay.

Practice Objective
After working through this practice, students are expected to understand the self-holding
concept in the electro-hydraulic control system.
Procedure
1. Connect the hydraulic circuit according to Figure 2.2(a).
2. Connect the electric circuit as shown in Figure 2.2(b).
3. Validate the hydraulic circuit and the electric circuit for any misconnection.
4. Turn the hydraulic power unit ON. Adjust the pressure to 25 to 35 MPa at the
pressure-limiting valve.
5. Turn the DC Power Supply ON. Set the voltage to be 24V.
6. Turn S0 ON.
7. Press S1; verify if the piston rod continue to extend to its maximum limit.
8. Press S2; verify if the piston rod retracts.
9. Once you finish the practice, turn OFF of the Hydraulic Power Unit and DC Power
Supply.

S0

A
1

+24V
4

B
A

B
S1

K1

K1

Y1
P

T
P

1
LS

T
P

K1

Y1

0V
Ts
4
5

(a)HydraulicCircuit

(b)ElectricalCircuit

Figure 2.2: Circuit drawing of hydraulic and electrical circuits for Task 2
Assignment
Based on your observation, explain the differences between Task 1 and Task 2, in term of:
1. The operation and function of the electrical circuit.
2. The operation and function of the hydraulic circuit
~End~

10

Task 3: Implementing Basic Logic Functions in Electro-hydraulic Circuit.

Practice Objective
After working through this practice, students are expected to be able to relate the installation of
parallel and serial electric circuit of with the basic logic functions (OR/AND/NOT).
Assignment
By using hydraulic circuit shown in Figure 2.2(a), design electrical circuits to perform the
following tasks:
1. Task #1: Cylinder is extended whenever S1 and S2 are pressed.
2. Task #2: Cylinder is extended whenever S1 or S2 are pressed.
3. Task #3: Cylinder is extended whenever S1 is pressed and S2 is not pressed.
For each task (1 to 3), you are required to:
1.
2.
3.
4.

~End~

Write down the truth table of the operation.

Formulate the logic equations based on the truth table.
Design the electrical circuit that you have designed.
Validate (and record) the experiment observation.

11

2.2. Electro-Pneumatic
Task 1: Actuation of the 5/2 Way Directional Control Valve (DCV).
Practice Objective
After working through this practice, students are expected to understand the basic operation of
the electro-pneumatic control circuit using a double-acting cylinder.
Procedure
1. Connect the pneumatic circuit as shown in Figure 2.3(a).
2. Connect the electric circuit as shown in Figure 2.3(b).
3. Validate the pneumatic circuit and electric circuit for any misconnection.
4. Turn the pneumatic power unit ON. Adjust the pressure to 2 to 5 bars at the pressurelimiting valve.
5. Turn the electrical power unit ON.
6. Press S1 and verify if the piston rod of the pneumatic cylinder extends.
7. Press S2 and verify if the piston rod of the pneumatic cylinder retracts.
8. After you complete the experiment, turn OFF of the pneumatic power unit and
electric power unit.
1

+24V

3
S2

S1
4
4

1
S1

S2
2

B1

B2
1

1
2

B1

B2

0V
1

(a)PneumaticCircuit

(b)ElectricalCircuit

Figure 2.3: Circuit drawing of pneumatic and electrical circuits for Task 1
Assignment
Based on your observation, fill Table 2.2.

S1
Not pressed
Not pressed
Pressed
Pressed

Table 2.2: Truth table for Task 1.

S2
Double-Acting Cylinder
(Extend/Retract/No change)
Not pressed
Pressed
Not pressed
Pressed

Based on your understanding, describes the expected result if both solenoids (B1 and B2) in Figure
2.3(b) are swapped.
~End~
12

Task 2: Self-holding (Memory) Electro-Pneumatic Circuit Using Relay.

Practice Objective
After working through this practice, students are expected to understand the self-holding
concept in the electro-pneumatic control system.
Procedure
1. Connect the pneumatic circuit and electric circuit as shown in Figure 2.4(a) and (b).
2. Validate the pneumatic circuit and electric circuit for any misconnection.
3. Turn the pneumatic power unit ON. Adjust the pressure to 2 to 5 bars at the pressurelimiting valve.
4. Turn the electrical power unit ON.
5. Press and hold S1. Verify if the piston rod of the pneumatic cylinder extends.
6. Release S1. Verify if the piston rod of the pneumatic cylinder extends.
7. Record your observation.
8. Press the switch S2 and verify if the piston rod of the pneumatic cylinder retracts.
9. Replace the current electric circuit to the electrical circuit shown in Figure 2.5.
Repeat procedure #3 to #7. Based on your observation, explain the differences
observed between these two electrical circuits.
10. After you complete the experiment, turn OFF of the pneumatic power unit and
electrical power unit.
1

+24V

3
S1
4

2
B1
1
2

B1
1

0V

(a)PneumaticCircuit

(b)ElectricalCircuit

Figure 2.4: Circuit drawing of pneumatic and electrical circuits for Task 2

~End~

13

+24V

S1

Z
4

3
Z

1
S2
2
A1
B1

Z
A2

0V

2
3

Figure 2.5: Self-holding electrical circuit

~End~

14

Task 3: Implementing Basic Logic Functions in Electro-pneumatic Circuit.

Practice Objective
After working through this practice, students are expected to be able to relate the installation of
parallel and serial electric circuit with the basic logic functions (OR/AND/NOT).
Assignment
By using the pneumatic circuit as shown in Figure 2.6, try out different electrical circuits as
shown in Figure 2.7(a) to Figure 2.7(c).

2
B1
1
2

Figure 2.6: Pneumatic circuit for Task 3

~End~

15

+24V

+24V

S1

S1
4

S2
4

+24V

S1
4

3
S2
4

B1

0V

B1

B1

0V

(a)

0V

(b)

(c)

Figure 2.7: Electrical Circuits for Task 3

For each scenario (Figure 2.7(a) to Figure 2.7(c)), you are required to:
1. Write down the truth table of the observed result.
2. Formulate the logic equation based on the truth table.
3. Identify which logic function is used.
Based on what you have learned in the previous section, design an electro-pneumatic circuit that
fulfill the following truth table (refer Table 2.3).
Table 2.3: Truth Table for Task 3
S1
S2
d
0
0
0
0
1
1
1
0
1
1
1
0
Note:
ForS1&S2:0=Notpress&1=Press
Ford:0=Retract&1=Extend
You are required to:
1.
2.
3.
4.
~End~

Formulate the logic equations based on the truth table.

Design the electro-pneumatic circuit you had designed.
Validate the design with the experiment observation.
Identify which logic function that has the same truth table as Table 2.3.
16

3.

PROBLEMS

3.1. Electro-Hydraulic
Application of Electro-hydraulic in Vehicle Lift.
Practice Objective
After working through this practice, students are expected to be able to design and implement
an electro-hydraulic circuit which behaves as vehicle lift.
Assignment
A vehicle lift as shown in Figure 3.1 has been widely used in the automobile service centres.

Figure 3.1: Vehicle lift

Design and demonstrate an electro-hydraulic circuit that meets the following requirements:
1. Use a 4/3 single-solenoid spring return control valve to actuate the cylinder.
2. The cylinder should lift the car to half its maximum position when S1 is pressed. The
lift will stop after being contact with limit switch.
3. Then, the cylinder should lift the car to its maximum position when S2 is pressed.
4. If the S3 is pressed at any period of time, the cylinder will return to its initial/home
position.
5. Incorporates memory circuit for all the pushbuttons (S1, S2 and S3).
6. Include two physical contact switches to detect whether all the car tires are on the
platform for safety purposed. Requirement 2 to 4 can only be execute if and only if
all the car tires are detected by the contact switches.
In your report, please include (but not limited to) the following information:
1. The truth table of the expected result.
2. The logic equations based on the truth table.
3. The hydraulic and electrical circuits that you had designed.

~End~

17

Problem #2: Application of Electro-Pneumatic in Box Sorting

Practice Objective
After working through this practice, students are expected to design and install an electropneumatic circuit using multiple cylinders with sequence motion.
Assignment
Figure 3.2 illustrates the application of electro-pneumatic system in a box sorting system.
The objective of this assignment is to place the boxes either into container A or B
accordingly based on size. You are needed to design an electro-pneumatic circuit for the
following requirements:
1. Conveyor belt is used to move the boxes.
2. Cylinder c is used to push the box to the continuously moving conveyor belt.
3. Stop the conveyor belt if the big box is detected on the conveyor belt and use
cylinder d to push the big box into container A.
4. The small box will be delivered into container B which located at the end of the
conveyor.

Figure 3.2: Box sorting in industry

Your electro-pneumatic design must fulfill (but not limited to) the following criteria:
1. Use pushbutton S1 and S2 to respectively start and stop the operation of the system.
2. Use the proximity sensors / limit switches to detect the positions of cylinders and to
determine the size of boxes.
3. Use two 5/2 ways DCV with spring return.
4. Incorporates memory circuit for the pushbutton.
Once you have completed the design, please demonstrate your result to the facilitator. In
your report, please include (but not limited to) the electro-pneumatic circuit you had
designed.

~End~

18