Fundamentals of
Electrohydraulics
Collection of
Transparencies
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a
095051 GB
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095051
E.-HYDR-FOLIEN.
D:OT-TP601-GB
07/2001
Dieter Scholz
Doris Schwarzenberger
18.07.2001, Beatrice Huber
Festo Didactic GmbH & Co., D-73770 Denkendorf, 2001
Internet: [Link]/didactic
e-mail: did@[Link]
The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Foreword
This set of overhead transparencies has been designed for use with the basic level
of the technology package TP600 Electrohydraulics. The set of overhead
transparencies and the technology package form part of the Learning System for
Automation from Festo Didactic GmbH & Co.
The 30 transparencies in this set have been optimised from the didactic and
methodological points of view. Each transparency is accompanied by a short text
which provides the trainer with a quick overview of the training contents of the
transparency concerned.
Training contents
Basic principles of electrohydraulics
Function and use of electrohydraulic components
Basic principles of electrical engineering
Production and interpretation of standard hydraulic and electrical circuit
diagrams
The text sheet includes a complete illustration of the transparency, in certain cases
with additional explanations and legends which the trainer can enter on the
transparency in the course of a training session.
The advantages of this concept are:
The trainer can add to the transparencies step by step in the course of a training
session.
The trainer is thus able to create a lively and interesting atmosphere.
The provision of accompanying text means less preparation work for the trainer.
New!
Electronic presentation
The enclosed CD-ROM contains the entire overhead transparencies and
accompanying text of this edition in an electronically presentable form in the files
Electrohydraulics _transparencies.pdf and Electrohydraulics _text.pdf. In
addition to the screen presentation, which can be made in any order, the contents
can be printed out and text and graphics can be used for your own training
preparations, insofar as the functionality of the required Adobe Acrobat Reader
permits this. This freely distributable software is available on the CD-ROM in the
currently valid English version for Windows 95/98/NT for installation in the directory
Acrobat_Reader. Please start the file [Link] and follow the subsequent
dialogue.
Festo Didactic GmbH & Co. Electrohydraulics
Contents
Electrohydraulic press _______________________________________ Transparency 1
Schematic layout of an electrohydraulic installation ______________ Transparency 2
Electrical power supply unit __________________________________ Transparency 3
Electrical circuit ____________________________________________ Transparency 4
Measuring circuits __________________________________________ Transparency 5
Ohms law _________________________________________________ Transparency 6
Rectifiers __________________________________________________ Transparency 7
Analogue, digital and binary __________________________________ Transparency 8
Momentary and sustained contact switches _____________________ Transparency 9
N/O, N/C and changeover contacts ___________________________ Transparency 10
Limit switches _____________________________________________ Transparency 11
Proximity switches _________________________________________ Transparency 12
Solenoid (electromagnet) ___________________________________ Transparency 13
Electrohydraulic converters (solenoid valves)___________________ Transparency 14
Dry solenoids wet solenoids________________________________ Transparency 15
Solenoid valve connections__________________________________ Transparency 16
Relays and contactors ______________________________________ Transparency 17
Direct activation indirect activation __________________________ Transparency 18
Signal inversion ___________________________________________ Transparency 19
Latching__________________________________________________ Transparency 20
Circuit diagram ____________________________________________ Transparency 21
Hydraulic power pack_______________________________________ Transparency 22
Hydraulic circuit ___________________________________________ Transparency 23
Electrical power hydraulic power ____________________________ Transparency 24
Power losses______________________________________________ Transparency 25
Pressure switches__________________________________________ Transparency 26
4/3-way solenoid valve _____________________________________ Transparency 27
4/3-way solenoid valve, piloted ______________________________ Transparency 28
Electrical safety____________________________________________ Transparency 29
Hydraulic safety ___________________________________________ Transparency 30
Festo Didactic GmbH & Co. Electrohydraulics
Electrohydraulic press
Function units
Motor with hydraulic pump
Control panel
Valve manifold
Cylinder
The hydraulic press is controlled via the electrical control panel.
Electrical signals are used to activate the valves in the hydraulic installation.
The electrohydraulic press is used to form rectangular troughs.
Motor with
hydraulic pump
Valve manifold
Actuator
(cylinder)
Control pane
Festo Didactic GmbH & Co. Electrohydraulics
Electrohydraulic press
Festo Didactic GmbH & Co.
TP 601, Transparency 01
Schematic layout of an electrohydraulic installation
Division of installation into signal control section and hydraulic power section.
Signal control section
Input and processing of electrical signals.
Solenoid valves form the interface between the electrical signal control section and
the hydraulic power section.
Controls the flow of hydraulic fluid by means of solenoid valves. Actuators convert
hydraulic energy into motions.
Power section
Signal control section
Hydraulic
cylinder
Signal
processing
Signal
input
Solenoid
valve
Power
supply
Hydraulic power section
Hydraulic
power
supply
(conversion)
Festo Didactic GmbH & Co. Electrohydraulics
Schematic layout of an electrohydraulic installation
Power section
Signal control section
Festo Didactic GmbH & Co.
TP 601, Transparency 02
Electrical power supply unit
Connection to mains supply.
Supplies signal control section with specified or maximum voltage and current
values.
Functions in
power supply unit
Voltage transformation
Rectification
Smoothing
Stabilisation
Fuse protection
In mobile hydraulic systems, rechargeable battery systems or generators are used
as a power supply for the signal control section.
230V
AC DC
24V
50 C
TR
Transformer
Rectifier
Smoothing Stabilisation
Fuse
Festo Didactic GmbH & Co. Electrohydraulics
Electrical power supply unit
230V
AC DC
24V
TR
Festo Didactic GmbH & Co.
T
TP 601, Transparency 03
Electrical circuit
A circuit consists of at least a power source, a load device and connecting lines.
Electrical current will flow only in a closed circuit.
Technical direction
of current flow
Electrical current flows from the positive terminal of the power supply to the
negative terminal.
Figure A
Closed circuit without power supply.
Figure B
Introduction of a power supply to complete the circuit.
Festo Didactic GmbH & Co. Electrohydraulics
Electrical circuit
A
Festo Didactic GmbH & Co.
TP 601, Transparency 04
Measuring circuits
Voltage measurement
The voltage drop across a load device is measured in parallel with the device.
Current measurement
Electrical current is measured in series.
Voltage measurement
Current measurement
Festo Didactic GmbH & Co. Electrohydraulics
Measuring circuits
Festo Didactic GmbH & Co.
TP 601, Transparency 05
Ohms law
Ohms law
Describes the relationship between current (I), voltage (V) and resistance (R).
With ohmic resistances, the current rises in linear proportion to the voltage.
The value pairs for a constant resistance lie on a straight line. The current I is
proportional to the voltage V.
Mathematical formula for Ohms law:
V=RI
I=
V=RI
I=V:R
Resistance R
Voltage V
10 V
20 V
30 V
40 V
Relay
0.5 A
1.5 A
2.0 A
Solenoid coil
0.33 A 0.66 A 1.0 A
V
R
1.33 A
2.0
A
1.5
A
R
1.0 A
1.0
Graph
0.5
0
10
20
30 V 40
Festo Didactic GmbH & Co. Electrohydraulics
Ohms law
Voltage V
10 V
20 V
Resistance R
30 V
40 V
Relay
Solenoid coil
1.0
2.0
A
1.5
0.5
0
10
20
30 V 40
V
Festo Didactic GmbH & Co.
TP 601, Transparency 06
Rectifiers
Rectifiers convert AC to DC.
Diodes are conductive in only one direction.
The polarity of the negative half-wave of the alternating voltage is reversed.
The pulsating voltage is smoothed using a capacitor and filters (reactance coil,
resistor).
~
C
Diodes
Voltage
smoothing
Voltage
retification
Festo Didactic GmbH & Co. Electrohydraulics
Rectifiers
~
t
Festo Didactic GmbH & Co.
t
TP 601, Transparency 07
Analogue, digital and binary
Analogue values
Analogue values describe continuous functions, such as the continuous filling of a
bucket of water.
Digital values
Digital values describe integer parts of a maximum value. A dice, for example, shows
one of six possible numbers.
Binary values
Binary values are a special form of digital values. They can assume only two values,
such as in the case of a switch, which can only be on or off.
halffull
empty
Filling time t
6
5
4
3
2
1
0
On 1
Light
full
Value
Volume V
Experiments with dice
Off 0
Switching
time point
Time t
Festo Didactic GmbH & Co. Electrohydraulics
Analogue, digital and binary
Filling time t
Festo Didactic GmbH & Co.
Light
Value
Volume V
Experiments with dice
Time t
TP 601, Transparency 08
Momentary and sustained contact switches
Actuation of contacts.
Momentary contact switch
A momentary contact switch has a rest position and an actuated position.
Sustained contact switch
A sustained contact switch has two detents. It thus has two rest positions.
Momentary and sustained switches can close or open current paths or switch from
one current path to another.
Festo Didactic GmbH & Co. Electrohydraulics
Momentary and sustained contact switches
Festo Didactic GmbH & Co.
TP 601, Transparency 09
10
N/O, N/C and changeover contacts
N/O
Contact normally open in rest position.
N/C
Example: Momentary-contact switch
Changeover contact
N/O and N/C contacts in a single housing; one contact is open while the other is
closed.
The designations of the switch contacts are governed by the European standard
EN 50012.
Switch elements
Connection
(N/O contact)
3
4
1
2
Connection
(N/C contact)
Festo Didactic GmbH & Co. Electrohydraulics
N/O, N/C and changeover contacts
Festo Didactic GmbH & Co.
TP 601, Transparency 10
11
Limit switches
Determining the position of a positioning slide.
Electrical contacts are actuated when a defined intermediate or end position is
reached.
Limit switches can be connected up as N/O, N/C or changeover contacts.
Switch lever
Stem (insulated)
Contact
Snap-action
mechanism
Festo Didactic GmbH & Co. Electrohydraulics
Limit switches
Festo Didactic GmbH & Co.
TP 601, Transparency 11
12
Proximity switches
Inductive
Signal is generated by the presence of any material with good conductivity in an
oscillating magnetic field.
Capacitive
Signal is also generated by all insulators with high dielectric constants in an
electrical field.
Optical
Signal is generated when light barriers are interrupted or when light is reflected
back to an optical sensor.
Reed switches
Signal is generated by magnets whose fields close the built-in contacts in the switch.
inductive
Metal
Reed switch
Magnet
capacitive
Metal
or
Insulator
optical
reflective
component
magnetic
Festo Didactic GmbH & Co. Electrohydraulics
Proximity switches
Festo Didactic GmbH & Co.
TP 601, Transparency 12
13
Solenoid (electromagnet)
A magnetic field with concentric field lines is created around a conductor carrying an
electrical current.
A coil carrying an electrical current develops a uniform magnetic field in its axial
direction due to the overlapping of field lines.
By appropriate alignment of elementary magnets, an iron core can be made into a
switchable electromagnet.
Field around
a conductor
Iron core
Coil
Coil
Festo Didactic GmbH & Co. Electrohydraulics
Solenoid (electromagnet)
+
-
Festo Didactic GmbH & Co.
TP 601, Transparency 13
14
Electrohydraulic converters (solenoid valves)
Convert electrical signals into hydraulic switching operations.
The switching armature is drawn into the coil, which acts as a magnet.
This produces a displacement of the actuating piston in the hydraulic 4/2-way valve.
Switching armature
4/2-way solenoid valve
Festo Didactic GmbH & Co. Electrohydraulics
Electrohydraulic converters (solenoid valves)
Festo Didactic GmbH & Co.
TP 601, Transparency 14
15
Dry solenoids wet solenoids
Dry solenoid
The solenoid is separated from the hydraulic fluid; a seal is required on the stem.
Advantage
Simple construction
Wet solenoid
The armature chamber of the solenoid is filled with hydraulic fluid, the solenoid
operates in oil.
Advantages
Low friction
Little abrasion
Good heat dissipation
Long service life
seal
Dry solenoid
Wet solenoid
Festo Didactic GmbH & Co. Electrohydraulics
Dry solenoid
Festo Didactic GmbH & Co.
Wet solenoid
TP 601, Transparency 15
16
Solenoid valve connections
Connector components
Solenoid with plug base
Cable with connector socket
Electrical signals are transmitted via standard connectors.
Advantages
Reliable alignment of connections
Connections can be attached and detached quickly
Protected against dust and water
2
3
1
Electrical
connections
Protective earth connection
Plug base
Festo Didactic GmbH & Co. Electrohydraulics
Solenoid valve connections
2
3
1
Festo Didactic GmbH & Co.
TP 601, Transparency 16
17
Relays and contactors
Definition
Switches which are actuated and held in their actuated positions
electromagnetically.
Used to separate control and power circuits.
Special feature
of relays
Special feature
of contactors
Each main contact is of double-break type (contacts used as main contacts),
suitable for
all power ratings from small to very large
only N/O and N/C contacts
Hinged-armature design
Single-break contacts
Used for logic gating of signals
(generally) changeover contacts
Coil
Iron core
Armature
Return spring
Contacts
+
+
Contacts
Return spring
Hinged-armature solenoid
Coil
Plunger-armature solenoid
Festo Didactic GmbH & Co. Electrohydraulics
Relays and contactors
+
-
+
-
Festo Didactic GmbH & Co.
TP 601, Transparency 17
18
Direct activation indirect activation
Direct activation
Connection of a solenoid valve via a switch (Fig. A).
Indirect activation
Connection of a solenoid valve via a relay (Fig. B).
Advantage of
indirect activation
Separation of control and power circuits
The current passing through switch S1 (Fig. B) is lower, and the service life of the
switch is significantly greater.
24 V
S1
S1
Y1
0V
24 V
K1
3
4
K1
3
4
Y1
0V
Festo Didactic GmbH & Co. Electrohydraulics
Direct activation
24 V
0V
Festo Didactic GmbH & Co.
Indirect activation
24 V
0V
TP 601, Transparency 18
19
Signal inversion
The output signal is inversely proportional to the input signal.
Figure A
Signal inversion at relay K1.
Figure B
Signal inversion at switch S1.
The switching elements are shown under zero-voltage conditions.
A
1
24 V
S1
2
3
K1
K1
24 V
1
S1
2
1
K1
K1
Y1
0V
3
4
Y1
0V
S1
K1
Y1
S1
K1
Y1
Festo Didactic GmbH & Co. Electrohydraulics
Signal inversion
A
24 V
S1
2
3
K1
K1
S1
Y1
2
1
K1
K1
0V
3
4
Y1
0V
S1
Festo Didactic GmbH & Co.
24 V
K1
Y1
S1
K1
Y1
TP 601, Transparency 19
20
Latching
Latching only with indirect activation.
Actuation of switch S1: Relay K1 reverses holding the current path of K1 closed.
The actuation of switch S2 interrupts the latched current path.
24 V
S1
2
3
4
K1
S2
K1
3
3
K1
4
1
2
Y1
3
4
S1
S2
K1 & Y1
dominant on
0V
Festo Didactic GmbH & Co. Electrohydraulics
Latching
24 V
S1
2
3
4
K1
S2
K1
3
3
K1
4
1
2
S1
S2
K1 & Y1
Y1
0V
Festo Didactic GmbH & Co.
TP 601, Transparency 20
21
Circuit diagram
Lines of potential with constant voltage are drawn horizontally.
Current paths are drawn vertically and numbered consecutively.
Circuit symbols are shown in the direction of current flow.
Switching elements are generally shown under zero-voltage conditions.
Latching to guard against sticking of relay contacts in current paths 6 and 7.
24 V
S0
1
3
4
S1
3
3
4
K1
4
3
4
S2
5
3
4
K2
6
3
4
K1
K2
K1
A1
A2
K2
A1
A2
Y1
7
3
K2
4
1
2
K1
3
4
1
2
Y2
0V
Festo Didactic GmbH & Co. Electrohydraulics
Circuit diagram
S0
3
4
S1
3
4
K1
3
4
S2
3
4
K2
3
4
K1
K2
K1
Festo Didactic GmbH & Co.
A1
A2
K2
A1
A2
Y1
K2
4
1
2
K1
3
4
1
2
Y2
TP 601, Transparency 21
22
Hydraulic power pack
Hydraulic power pack for use in stationary hydraulic systems.
Power is delivered via the pressure medium using a pump and drive motor.
The pack incorporates devices to remove air, water and solid particles from the
hydraulic fluid.
Pressure relief valve
(safety valve)
Pressure line
Electric motor n = 1500 rpm
Return line
Hydraulic pump
Suction pipe
Air filter
Suction filter
Fluid level indicator
Filler filter
Cleaning aperture
Baffle plate
Drain screw
Festo Didactic GmbH & Co. Electrohydraulics
Hydraulic power pack
Festo Didactic GmbH & Co.
TP 601, Transparency 22
23
Hydraulic circuit
Hydraulic systems consist of open or closed circuits.
Hydraulic fluid is used as an energy carrier.
This energy is output via cylinders and motors.
Relieved hydraulic fluid is returned to the tank or hydraulic pump.
Hydraulic cylinder
Electrohydraulic
power valve
Hydraulic
pump
Motor
Return
line
Safety
valve
Hydraulic pump
open
Hydraulic
motor
Motor
Filter
Safety
valve
Feed pump
(top-up for
leakage losses)
Safety valve
closed
Festo Didactic GmbH & Co. Electrohydraulics
Hydraulic circuit
open
Festo Didactic GmbH & Co.
closed
TP 601, Transparency 23
24
Electrical power hydraulic power
Electric motor
Driven by electric current on the basis of a potential difference.
Electrical power is the product of voltage and current
Pelectr. = V I (unit: watts).
Driven via fluid flow on the basis of a pressure difference.
Hydraulic power is the product of pressure and flow rate
Phydr. = p Q (unit: watts).
Pelectr. = V I
Phydr. = p q
Flow
rate q
Pressure p
Current I
Voltage V
Hydraulic motor
Electric motor
Gear motor
Festo Didactic GmbH & Co. Electrohydraulics
Electrical power
Hydraulic power
+
-
Festo Didactic GmbH & Co.
TP 601, Transparency 24
25
Power losses
Efficiency of electric motors
Frictional losses
Magnetic losses
Efficiency of hydraulic pump Frictional losses
Volumetric losses
Valves, piping, tubing
Pressure losses dp
Power losses expressed by P = dp Q
Hydraulic motors
and cylinders
Frictional losses
Volumetric losses
Frictional and
pressure losses
Power losses
Frictional and
volumetric losses
Frictional,
volumetric and
magnetic losses
Phydr. loss = ,p q
Festo Didactic GmbH & Co. Electrohydraulics
Power losses
Festo Didactic GmbH & Co.
TP 601, Transparency 25
26
Pressure switches
Actuation of electrical contacts when a defined minimum pressure is reached.
The minimum pressure (switching point) can be varied by means of an adjustable
spring.
Example shows switching at approx. 4 bar with rising or falling pressure.
Generally connected up in practice as a changeover contact.
2 3
Symbolic representation
in hydraulic circuit diagram
Symbolic representation
in electrical circuit diagram
p
1
1
3
2
Pressure
p
4 bar
c
b
Hysteresis
Time t
a/c Switching point with rising pressure
b
Switching point with falling pressure
Festo Didactic GmbH & Co. Electrohydraulics
Pressure switches
2 3
p
1
1
3
2
Pressure
p
4 bar
Time t
Festo Didactic GmbH & Co.
TP 601, Transparency 26
27
4/3-way solenoid valve
Valve spool is directly actuated by solenoids.
Actuation on left
The piston spool is displaced to the right and creates the connections P A
and B T.
Rest position
Rest position produced by spring centring of piston spool. All inputs of the 4/3-way
valve are closed in this position.
b
a
Festo Didactic GmbH & Co. Electrohydraulics
4/3-way solenoid valve
Festo Didactic GmbH & Co.
TP 601, Transparency 27
28
4/3-way solenoid valve, piloted
Direct activation of pilot spool via solenoids.
Actuation on left
The pilot piston spool is displaced to the right, and hydraulic fluid is directed to the
right-hand side of the main control spool, creating the connections P A and B T.
Rest position
Rest position produced by spring centring of pilot and main piston spools. All ports
of the 4/3-way valve are closed at the main valve.
Simplified symbol
Detailed symbol
Festo Didactic GmbH & Co. Electrohydraulics
4/3-way solenoid valve, piloted
T
Festo Didactic GmbH & Co.
TP 601, Transparency 28
29
Electrical safety
EMERGENCY STOP button placed in an easily accessible position
Protection against voltages
Protection by means of insulation
Protection by means of earthed conductive housings
Safety isolation by means of transformers
1) Switch off
2) Check
3) Carry out work
EMERGENCY
STOP
Safety insulation
Protective earth
Safety isolation
Additional
insulation
L1
PE
220 V AC
24 V
Basic insulation
Festo Didactic GmbH & Co. Electrohydraulics
Electrical safety
Safety insulation
Festo Didactic GmbH & Co.
Protective earth
Safety isolation
TP 601, Transparency 29
30
Hydraulic safety
Safety regulations must be observed.
Switch off motor/pump
Depressurise accumulator
Lower load
Check pressure
Work can now be carried out by authorised trained personnel.
1) Switch off
motor/pump
2) Depressurise
accumulator
3) Lower
load
4) Check
pressure
Festo Didactic GmbH & Co. Electrohydraulics
Hydraulic safety
Festo Didactic GmbH & Co.
TP 601, Transparency 30
