JABATAN KEJURUTERAAN MEKANIKAL
POLITEKNIK UNGKU OMAR
SESI _____________
KOD KURSUS : DJJ40153
NAMA KURSUS : PNEUMATIC AND HYDRAULIC
NO & TAJUK LAB :
SEKSYEN KURSUS &
KUMPULAN LAB :
NAMA PENSYARAH KURSUS :
ARAHAN PENILAIAN:
1. Jawab semua/pilihan soalan dalam masa 2 hari (Rujuk SLT)
2. Jawapan adalah secara individu/berkumpulan.
3. Kembalikan soalan setelah selesai menjawab/Soalan boleh disimpan oleh pelajar.
4. Lain-lain arahan yang bersesuaian mengikut kursus.
NO. PENDAFTARAN NAMA CLO MARKAH
3 20
JUMLAH 20
Disediakan oleh: Disemak dan Disahkan oleh:
ISMANIZA BINTI ISMAIL KAMARUZZAMAN BIN DAUD
POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
PNEUMATICS AND HYDRAULICS LABORATORY
DJJ 40153
TABLE OF CONTENTS
PAGE
NO. TOPIC
1 SAFETY AND HEALTH 3-5
2 PRACTICAL 1: TRANSFER OF PARTS (Pneumatic) 6-8
PRACTICAL 2: HOPPER CONTROLLER (Electro
3 9-10
Pneumatic)
PRACTICAL 3: TRANSFER OF PARTS (Electro
4 11-12
Hydraulic)
PRACTICAL 4: PNEUMATIC AND
5 ELECTROPNEUMATIC CIRCUIT USING SIMULATION 13
SOFTWARE
6 LAB REPORT ASSESSMENT 14-17
COURSE Upon completion of this course, students should be able to:
LEARNING
OUTCOMES 1. Apply the basic concept and function of pneumatics and hydraulics
system.(C3,PLO1)
2. Design pneumatic, electro-pneumatic and hydraulic circuit according to
assigned tasks.(C5, PLO3)
3. Perform experiment on pneumatic, electro-pneumatic and hydraulic
circuit during practical session.(P4, PLO5)
Disediakan oleh: Disemak dan Disahkan oleh:
ISMANIZA BINTI ISMAIL KAMARUZZAMAN BIN DAUD
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
1.0 SAFETY AND HEALTH :
All students must read and understand the information in this document with
regard to laboratory safety and emergency procedures prior to the first laboratory
session. Your personal laboratory safety depends mostly on YOU. Effort has
been made to address situations that may pose a hazard in the lab but the
information and instructions provided cannot be considered all-inclusive.
Students must adhere to written and verbal safety instructions throughout the
academic term. Since additional instructions may be given at the beginning of
laboratory sessions, it is important that all students arrive at each session on time.
With good judgement, the chance of an accident in this course is very small.
Nevertheless, research and teaching workplaces (labs, shops, etc.) are full of
potential hazards that can cause serious injury and or damage to the equipment.
Working alone and unsupervised in laboratories is forbidden if you are working with
hazardous substances or equipment. With prior approval, at least two people should
be present so that one can shut down equipment and call for help in the event of an
emergency.
Safety training and/or information should be provided by a faculty member,
teaching assistant, lab safety contact, or staff member at the beginning of a new
assignment or when a new hazard is introduced into the workplace.
1.1. Emergency Response
It is your responsibility to read safety and fire alarm posters and follow
the instructions during an emergency
Know the location of the fire extinguisher and know how to use them.
Notify your instructor immediately after any injury, fire or explosion, or
spill.
Know the building evacuation procedures.
1.2. Common Sense
Good common sense is needed for safety in a laboratory. It is expected
that each student will work in a responsible manner and exercise good
judgement and common sense.
If at any time you are not sure how to handle a particular situation, ask
your Teaching Assistant or Instructor for advice.DO NOT TOUCH
ANYTHING WITH WHICH YOU ARE NOT COMPLETELY FAMILIAR!!!
It is always better to ask questions than to risk harm to yourself or
damage to the equipment.
1.3. Personal and General laboratory safety
Never eat, drink, or smoke while working in the laboratory.
Read labels carefully.
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
Do not use any equipment unless you are trained and approved as a user
by your supervisor.
Wear safety glasses or face shields when working with hazardous
materials and/or equipment.
Wear gloves when using any hazardous or toxic agent.
Clothing: When handling dangerous substances, wear gloves, laboratory
coats, and safety shield or glasses. Shorts and sandals should not be
worn in the lab at any time. Shoes are required when working in the
machine shops.
If you have long hair or loose clothes, make sure it is tied back or
confined.
Keep the work area clear of all materials except those needed for your
work. Coats should be hung in the hall or placed in a locker. Extra books,
purses, etc. should be kept away from equipment that requires air flow or
ventilation to prevent overheating.
Disposal - Students are responsible for the proper disposal of used
material if any in appropriate containers.
Equipment Failure - If a piece of equipment fails while being used, report
it immediately to your lab assistant or tutor. Never try to fix the problem
yourself because you could harm yourself and others.
If leaving a lab unattended, turn off all ignition sources and lock the
doors.
Clean up your work area before leaving.
Wash hands before leaving the lab and before eating.
1.4. Electrical safety
Obtain permission before operating any high voltage equipment.
Maintain an unobstructed access to all electrical panels.
Wiring or other electrical modifications must be referred to the Workshop
Coordinator.
Avoid using extension cords whenever possible. If you must use one,
obtain a heavy- duty one that is electrically grounded, with its own fuse,
and install it safely. Extension cords should not go under doors, across
aisles, be hung from the ceiling, or plugged into other extension cords.
Never, ever modify, attach or otherwise change any high voltage
equipment.
Always make sure all capacitors are discharged (using a grounded cable
with an insulating handle) before touching high voltage leads or the
"inside" of any equipment even after it has been turned off. Capacitors
can hold charge for many hours after the equipment has been turned off.
When you are adjusting any high voltage equipment or a laser which is
powered with a high voltage supply, USE ONLY ONE HAND. Your other
hand is best placed in a pocket or behind your back. This procedure
eliminates the possibility of an accident where high voltage current flows
up one arm, through your chest, and down the other arm.
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
1.5. Mechanical safety
When using compressed air, use only approved nozzles and never
directs the air towards any person.
Guards on machinery must be in place during operation.
Exercise care when working with or near hydraulically- or pneumatically-
driven equipment. Sudden or unexpected motion can inflict serious injury.
1.6 . Additional Safety Guidelines
Never do unauthorized experiments.
Never work alone in laboratory.
Keep your lab space clean and organized.
Do not leave an on-going experiment unattended.
Always inform your instructor if you break a component.
Check your glassware for cracks and chips each time you use it. Cracks
could cause the glassware to fail during use and cause serious injury to
you or lab mates.
Maintain unobstructed access to all exits, fire extinguishers, electrical
panels, emergency showers, and eye washes.
Do not use corridors for storage or work areas.
Do not store heavy items above table height. Any overhead storage of
supplies on top of cabinets should be limited to lightweight items only.
Also, remember that a 36" diameter area around all fire sprinkler heads
must be kept clear at all times.
Areas containing lasers, biohazards, radioisotopes, and carcinogens
should be posted accordingly. However, do not post areas unnecessarily
and be sure that the labels are removed when the hazards are no longer
present.
Be careful when lifting heavy objects. Only shop staff may operate
forklifts or cranes.
Clean your lab bench and equipment, and lock the door before you leave
the laboratory.
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
PRACTICAL 1: TRANSFER OF PARTS (Pneumatic)
1.0 LEARNING OUTCOMES:
At the end of this experiment, the student should be able to;
1.1 Build the pneumatic circuit.
1.2 Check the layout of the circuit.
2.0 EQUIPMENT / APPARATUS :
2.1 TWO (2) double-acting cylinders
2.2 TWO (2) 5/2 way pneumatic valves
2.3 FOUR (4) Pneumatic limit switches
2.4 ONE (1) Start Button (pneumatic)
2.5 A service unit
2.6 A manifold
2.7 Air hoses
3.0 SAFETY AND HEALTH :
As in pages 3 - 5
4.0 PRACTICAL CASE
4.1 Using a transfer station as in Figure 1, parts are to be transferred from a
vertical magazine to a processing station.
4.2 The parts are pushed by cylinder A and then transferred onto a chute by
cylinder B for transfer to the processing station.
4.3 The piston rod of cylinder B is only to retract after confirmation that cylinder
A has fully retracted.
4.4 The cycle is to start when a start button is pressed.
4.5 Limit switches are used to confirm cylinder positions.
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
CONVEYOR 2
CONVEYOR 1
Figure 1.1 : Transfer station
5.0 PROCEDURES :
5.1 Prepare the equipment based on the list.
5.2 Connect the circuit based on the pneumatic circuit given.
5.3 Make sure all connection fixed properly.
5.4 Turn the air into the system.
5.5 Push the start button and observe the movement of the cylinder.
5.6 Diconnect the circuit and release compressor pressure.
Pneumatic Circuit
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
Figure 1.2 : Pneumatic circuit
5.0 RESULTS/DATA :
5.1 Record your results and observations in a lab report.
PRACTICAL 2: HOPPER CONTROLLER
(Electro pneumatic)
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
1.0 LEARNING OUTCOMES:
At the end of this experiment, the student should be able to;
1.1 Build the electrical and pneumatic circuit.
1.2 Check the layout of the circuit.
2.0 EQUIPMENT / APPARATUS :
2.1 An electrical distribution plate (transformer)
2.2 A button box ( Electrical Input signal)
2.3 A relay box
2.4 A 5/2 way double solenoid valve
2.5 A double acting cylinder
2.6 Two (2) electrical limit switch
2.7 A service unit & manifold & air hoses & electrical wires.
3.0 SAFETY AND HEALTH :
As in pages 3 - 5
4.0 PRACTICAL CASE
4.1 As a device in Figure 2.1 is to transfer materials from other materials
handling device to another.
4.2 When S1 switch pushed, a cylinder moves forward.
4.3 Raw materials then come out when the S1 switch, pushed.
4.4 Trigger S2 limit switch to move cylinder backward. It will close the hopper
and stopped the materials from coming out.
MATERIAL
LOADER
CYLINDER ORIFICE
Figure 2.1 : Device transfer material
5.0 PROCEDURES :
5.1 Prepare the equipment based on the list.
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
5.2 Connect the circuit based on the pneumatic circuit and electrical circuit
given.
5.3 Make sure all connection fixed properly.
5.4 Turn the air into the system.
5.5 Push the start button and observe the movement of the cylinder.
5.6 Diconnect the circuit and release compressor pressure.
Pneumatic Circuit
Figure 2.2 : Pneumatic circuit
Electrical Circuit
Figure 2.3 : Electrical circuit
6.0 RESULTS/DATA :
6.1 Record your results and observations in a lab report.
PRACTICAL 3: HOPPER CONTROLLER (Electro Hydraulic)
1.0 LEARNING OUTCOMES:
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
At the end of this experiment, the student should be able to;
Build the electrical and hydraulic circuit.
Check the layout of the circuit.
2.0 EQUIPMENT / APPARATUS :
An electrical distribution plate (transformer)
A button box ( Electrical Input signal)
A 4/2 way solenoid valve
A double acting cylinder
Electrical wires
A manifold
Hydraulic hoses
Hydraulic power pack
3.0 SAFETY AND HEALTH :
As in pages 3 - 5
4.0 PRACTICAL CASE
a) Selection devices (Figure 3.1) are used for transferring work pieces from
one conveyer belt 1 to conveyer belt 2.
b) Single button switch is used to extract the cylinder rod.
c) Extraction of the cylinder will move the rejected work piece off the
conveyer belt.
d) Upon releasing the button, the cylinder rod will retract to the original
position.
5.0 PROCEDURES
CONVEYOR 2
SELECTION
DEVICE
CONVEYOR 1
Figure 3.1 : Transferring Device
Prepare the equipment based on the list.
Connect the circuit based on the hydraulic circuit and electrical circuit given.
Make sure all connections are fixed properly.
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
Supply compressed air into the system.
Push the start button and observe the movement of the cylinder.
Record your findings.
Once completeted, diconnect the circuit and empty the compressor’s tank.
Figure 3.2: Hydraulic and Electrical Circuit
6.0 RESULTS/DATA :
6.1. Record your results and observations in a lab report.
PRACTICAL 4: PNEUMATIC AND ELECTROPNEUMATIC
CIRCUIT USING SIMULATION SOFTWARE
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
Figure 4.1 below shows the schematic a furnace and its door that to be controlled.
Design a circuit for the furnace door to be opened and closed using FluidSIM.
Figure 4.1: Furnace
1) Construct a pneumatic circuit by using single cylinder based on situation
above.
2) Construct an electro- pneumatic circuit by using double acting cylinder based
on situation above.
3) Construct a pneumatic circuit by using double acting cylinder based on
situation above.
4) Construct an electro-pneumatic circuit by using single cylinder based on
situation above:
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
LAB REPORT ASSESSMENT
A- Draw and label the Pneumatic/Hydraulic/Electrical Schematics
( ISO FORMAT COMPULSARY) – 4 MARKS
NAME:
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
B- Explain how the Lab/Practical Task functioned. (USE ONLY TECHNICAL
TERMS) – 3 MARKS
NAME:
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
C- Briefly explain the THEORY related to practical – 3 MARKS
NAME:
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POLYTECHNIC UNGKU OMAR
MECHANICAL ENGINEERING DEPARTMENT
D- Reflection (The knowledge or skill acquired from this Lab/Practical Task). – 2
MARKS
NAME:
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MECHANICAL ENGINEERING DEPARTMENT
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