Unit Description and General Aims

A comprehensive knowledge of hydraulics and/or pneumatics (H/P) is vital for design of efficient hydraulic and pneumatic systems (including individual machines), maintenance and troubleshooting. The student will gain a working knowledge of how to apply H/P to achieve desired outcomes. This unit will focus on a range of varied circuit configurations including components controlling both fluid pressure and flow. Furthermore, a good working knowledge of other items that makes up a circuit, such as, actuators: both linear (cylinders) and rotary (motors). The student will be able to apply electro-hydraulic technology, both proportional and servo-motor types. 

The student will learn to apply knowledge gained of hydrostatics and fluid flow theory to calculate circuit requirements such as load capacity, pipe sizes, heat generation and input power. This topic will also deal with correct system installation, how to achieve reliability in operation and troubleshooting of complete systems.  

Topics on the social, economic, and environmental issues arising from the implementation of H/P systems, especially when coupled with robotics and mechatronics will be evaluated. A well-proven PC based program will enable the student to design and test their own circuit designs. 

Learning Outcomes

On successful completion of this Unit, students are expected to be able to: 

1. Determine the economics, and other factors for an application, to utilise an industrial H/P system in preference to other systems and to delineate which system is best. 
   • Bloom’s Level 5 
2. Evaluate in detail what discrete components make up an H/P system. 
   • Bloom’s Level 5 
3. Judge, critique information on optimal design, operation, troubleshooting and maintenance of H/P systems. 
   • Bloom’s Level 5 
4. Formulate on the social, commercial, and regulatory impacts of installing or modifying H/P systems. 
   • Bloom’s Level 6 
5. Evaluate existing or propose new applications for industrial H/P systems. 
   • Bloom’s Level 5 
6. Reassemble design information of a system to satisfy end-user requirements 
   • Bloom’s Level 6 

Student Assessment

Overall requirements: To pass the unit, students must achieve at least 50% in the ‘Test (Invigilated)’ and pass the test. Additionally, a final overall score of 50% or higher, including all assessments, is required to successfully complete the unit. 

Prescribed and Recommended readings

Required textbook(s) 

1. Practical Hydraulic & Pneumatic Systems: Operations and Troubleshooting, IDC Technologies, Perth. 
2. J. Watton, Fundamentals of Fluid Power Control, 1st ed, Cambridge University Press, 2009 (Paperback 2014) 

Reference Materials 

1. Parr, A, 2013, Hydraulics and Pneumatics: A Technician’s and Engineer’s Guide, revised edn, Butterworth-Heinemann, ISBN-13: 978-0080966748. Online version available at: http://app.knovel.com/web/toc.v/cid:kpHPATEG01/viewerType:toc/root_slug:hydraulics-pneumatics-2 
2. Fluid Power Circuits and Controls – Fundamentals and Applications by John S. Cundiff, 2001. 
3. Other texts, peer-reviewed journals, and websites. To be advised during lectures. 

Unit Content

One topic is delivered per contact week, except for part-time 24-week units, where one topic is delivered every two weeks.

Topic 1 

Introduction to Fluid Power 

1. Introduction to Hydraulics and Pneumatics 
2. History of Hydraulics and Pneumatics 
3. Global importance, economics, and future 
4. Fluid power fundamentals 

Topic 2 

Hydraulic equipment components 

1. Hydraulic equipment components with respect to functionality: Hydraulic power pack; Actuators (linear and rotary); Valves (direction, pressure, flow, check and other valves); Accessories (reservoirs, accumulators, filters, heat exchangers, pipe, hoses, and fluid lines) 
2. Hydraulic circuits and applications 

Topic 3 

Hydraulic fluids, losses, and efficiency. 

1. Hydraulic safety 
2. Hydraulic fluids and viscosity. 
3. Energy losses in the hydraulic systems 
4. Reducing losses and improving efficiency 

Topic 4 

Control Devices and Systems 

1. Types of control: Closed loop & Open loop 
2. Regenerative hydraulic circuit 
3. Sequencing hydraulic circuit 
4. Automated reciprocating cylinder 
5. Locked cylinder 
6. Cylinder synchronising circuits 
7. Speed control of cylinders: Meter-in, Meter-out and Bleed-off circuits 
8. Accumulators in hydraulic circuits 
9. Load sensing 

Topic 5 

Hydraulic control and automation: Electrical, Electronic, and PLC Control 

1. Solenoid operated DCV: Solenoid plus pilot controlled DCV 
2. Servo valves: Flapper, Jet, Characteristic, Control 
3. Proportional valves: Force controlled; Stroke controlled 
4. Introduction to the programmable logic controller (PLC) 

Topic 6 

Pneumatic system components. 

1. Characteristics of pneumatic systems and standards 
2. Prime movers and air compressors 
3. Air receivers and storage 
4. Air generation, preparation, and distribution 
5. Pneumatic components: valves, actuators 
6. Pneumatic symbols 

Topic 7 

Pneumatic systems efficiency 

1. Compressed air systems 
2. Introduction to pneumatic efficiency 
3. Systems approach 
4. Compressors control methods 
5. Comparison of compressors 
6. Assessment of compressors and systems 
7. Energy efficiency opportunities 

Topic 8 

Pneumatic control and automation systems 

1. Introduction to pneumatic control systems 
2. Basic pneumatic circuits: Actuator control circuits 
3. Basic pneumatic circuits: Flow amplification, Signal inversion 
4. Basic pneumatic circuits: Memory function, Delay function 
5. Basic pneumatic circuits: ON-signal delay; OFF-signal delay 
6. Basic pneumatic circuits: Logic circuits (OR, AND, NOT) 
7. Sequence plan 
8. Electro-pneumatic Devices and Systems 

Topic 9 

Detailed analysis of hydraulic systems 

1. Select a ‘real’ machine, stationary or mobile, and analyse the use of components & their functionality in the application. Suggest improvements, etc.  

Topic 10 

Detailed analysis of pneumatic systems 

1. Detailed analysis of pneumatic systems Select a ‘real’ machine, stationary or mobile, and analyse the use of components & their functionality in the application. Suggest improvements, etc. 

Topic 11 

Maintenance and Troubleshooting of Fluid power systems 

1. General Maintenance 
2. Industrial hydraulic system maintenance and troubleshooting 
3. Industrial compressed air system maintenance and troubleshooting 

Topic 12

Unit Review

1. Recent trends and future scopes
2. Unit review

Software 

• Software: Automation Studio 
• Software information: Automation Studio is a comprehensive software for designing, simulating, and documenting fluid power and electrical systems. It is crucial for mechanical engineers as it enhances productivity, reduces errors, and facilitates efficient project management. Applications include designing hydraulic and pneumatic systems, troubleshooting, and training.
• Version: 7.0 
• Instructions:  N/A 
• Additional resources or files: https://www.famictech.com/en/Products/Automation-Studio/Educational-Edition 

Hardware 

• Hydraulics and Pneumatics Test rigs (available as a H5P interactive video module as well) 

Unit Changes Based on Student Feedback:

The due dates of unit assessments were spaced out, which alleviated student stress and provided sufficient time to work on assessments of various units in each semester.