MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
WINTER– 18 EXAMINATION
Subject Name: Model Answer Subject Code: 17608
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.

Q. Sub Answer Marking

No. Q. Scheme
N.

1 Attempt any FIVE

(a) Compare oil and air as a medium in fluid system

Ans:  When the system requirement is high speed, medium pressure (usually 6 to 8 bar)
and less accuracy of position, then pneumatic system is preferred.
 If the system requirement is high pressure and high precision, a fluid system with oil Four Points
4 Marks
is good.
 When the power requirement is high like in forging presses, sheet metal press, it is ( 01 mark to
impossible to use air system. Oil hydraulics is the only choice . each point )
 Air is used where quick response of actuator is required.
 If temperate variation range in the system is large, then use of air system may run
into condensation problems and oil is preferred.
 Air is non-explosive, it is preferred where fire/electric hazard are expected. Oil
systems are more prone to fire and electrical hazards and are not recommended in
such applications. Because air contains oxygen (about 20%) and is not sufficient
alone to provide
 Adequate lubrication of moving parts and seals, oil is usually introduced into the air
stream near the actuator to provide this lubrication preventing excessive wear and
oxidation. If the application requires only a medium pressure.(any four points)
(b) State applications of hydraulic system

Ans: 1)Industrial: Plastic processing machineries, steel making and primary metal extraction
applications, automated production lines, machine tool industries, paper industries,
loaders, crushes, textile machineries, R & D equipment and robotic systems etc.
2)Mobile hydraulics: Tractors, irrigation system, earthmoving equipment, material
handling equipment, commercial vehicles, tunnel boring equipment, rail equipment,
Page No: ____/ N
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
building and construction machineries and drilling rigs etc. Four Points
3)Automobiles: It is used in the systems like breaks, shock absorbers, steering system, 4 Marks
wind shield, lift and cleaning etc.
4) Marine applications: It mostly covers ocean going vessels, fishing boats and navel ( 01 mark to
equipment. each point )
5)Aerospace equipment : used in airplanes, rockets and spaceships (Any four
applications)
(c) Draw IS symbol for

Ans: i)Dead weight accumulator ii)Tandem Cylinder

1x4

Marks
iii)Unloading valve iv)Heat Exchanger

(d) Show the layers of hydraulic hose with a neat sketch. State materials used for each layer.

Ans: Layers of hydraulic hose as shown in figure

2 Marks

Material used for each layer:

Nitrile or synthetic rubber for petroleum-based hydraulic oil. alternatives like Viton or Teflon are
used with synthetic fluids like phosphate ester.
The cover protects the reinforcement layer. One consideration when determining the cover
material is resistance to attack from outside influences like chemicals, salt water, steam, UV 2 Marks
radiation and ozone. Common cover materials include nitrile, neoprene and PVC.

(e) Draw and explain meter in circuit

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Ans:

2 Marks

Meter-in circuit is a method by which a flow control valve is placed in

a hydraulic circuit in such a manner that there is a restriction in the amount of fluid
flowing to the actuator. If the flow control valve were not to be located, the extension
and retraction of the actuator which in this case is a cylinder, would have proceeded at
an unrestricted rate. The presence of the flow control valve enables restriction in the
fluid flow to the cylinder and thereby slowing down its extension. In the event of the
flow direction being reversed, the check valve ensures that the return flow bypasses the
flow control valve.The inlet flow into the cylinder is controlled using a flow-control valve. 2 Marks
In the return stroke, however, the fluid can bypass the needle valve and flow through
the check valve and hence the return speed is not controlled. This implies that the
extending speed of the cylinder is controlled whereas the retracing speed is not.

(f) Draw general layout of pneumatic system and state function of each component in it.

Ans: 2 Marks

Layout of Pneumatic system fig.

• Compressor: This unit compresses the air which is at atmospheric pressure. The
pressure of air increases
2 Marks
• Air reservoir/ Air Tank: This tank stores compressed air which is output of air
compressors.
• Moisture seperator: moisture (water vapour ) is seperated. Type-chemical or
mechanical
• Air filter-Air pressure regulator-Air lubricator: Filtered,pressure regulated fine
Page No: ____/ N
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
particles helps in proper lubrication of sliding or rotary parts of actuator or
valves.
• DCV/FCV:These valves direct flow of air,control flow of air,speed of actuators.
• Air actuators:These items are the heart of pneumatic system.These are taking
part in obtaining mechanical advantage.These are either linear or rotary
actuators.
• Air conducting elements:The compressed air flow through pipes,valves are
conducting elements.
(g) Forward stroke of double acting pneumatic cylinder needs to be controlled as
requirement, Draw a suitable circuit and name each component in it.

Ans:

4 Marks

2 Attempt any TWO

(a) Explain with sketch working of swash plate type axial piston pump.

Ans:

4 Marks

Swash plate type axial piston pump in fig.

Working:
It consists of swash plate which has angular surface with reference to the
cylinder block axis. The two or more cylinders are mounted parallel to the axis of driving 4 Marks
shaft, the piston rod ends are attached to the angular surface of swash plate with the
help of shoe and shoe plate.
When driving shaft is rotated it will cause reciprocating movements of pistons
Page No: ____/ N
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
in cylinders depending upon the angular surface movement with respect cylinder barrel.
Now since swash plate is inclined and block is rotating, the piston reciprocates inside the
barrel. The reciprocating motion of piston causes suction and delivery of fluid through
inlet and outlet ports which come in front of outlet of piston. (Sketch 4 marks & Working 4
Marks)
(b) Explain with sketch working of pilot operated pressure relief valve. How it is different
from direct acting type?

Ans: Pilot operated pressure relief valve as shown in figure

3 Marks

Working:
It is simplest type valve contains a poppet held in a seat against the spring force as
shown in figure . It consist of two ports and one of which is connected to the pump and
another is connected to the tank. The fluid enters from the opposite side of the poppet.
When the system pressure exceeds the preset value, the poppet lifts and the fluid is
escaped through the orifice to the storage tank directly. It reduces the system pressure 3 Marks
and as the pressure reduces to the set limit again the valve closes.
Different from direct acting type:
Direct-Operated Regulators respond directly to variations in downstream pressure
to provide the necessary flow and pressure to satisfy the system set point. Outlet
pressure opposes the balance force provided by the spring to determine the plug
position. Therefore, for direct-operated regulators, Outlet pressure is also considered
the loading force. 2 Marks
Pilot-Operated Regulators consist of the same essential components of direct-operated
units (plug and seat, diaphragm, spring) with the addition of a pilot which separates
Outlet pressure and the diaphragm loading force .The pilot requires an external sense
line connected to the downstream piping. Measuring pressure further downstream of
the valves allows for more accurate sensing of the true outlet pressure conditions as it
moves the sense point away from the flow turbulence generated by the plug and seat.
The pilot valve can simply and effectively be considered a second regulator, providing
additional control to the main regulator, improving overall sensitivity and, ultimately,
accuracy.
(c) State the meaning of pressure compensation in flow control valve. Draw a sketch of
pressure compensated flow control valve and explain its working.

Ans: In any hydraulic circuit there are slight variations in presence of oil. When pressure
changes the rate of flow changes but many circuits requires constant flow regardless of
input or output pressure variations in the circuit then the pressure compensated flow 2 Marks
control valve is used.

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Figure
3 Marks

Pressure compensated flow control valve as shown in fig.

It consists of hollow cylinder shaped poppet at the bottom of which there is a
fixed orifice. There is a spring inside a poppet as shown in fig. Pressurized oil entering
through the inlet port will apply full force on the bottom of the poppet and will try to
compress the spring by shifting the poppet to right the poppet will move to right and will
close the outlet port. Then movement of the poppet toward right will stop. Now flow of
oil through the orifice will start. Oil will occupy the bore of cylinder this flow of oil will 3 Marks
equalize the pressure on both ends of the poppet. The poppet will then balance.
During the process of poppet balancing, spring will expand and poppet will
move toward left thereby uncovering the outlet port. A balance will automatically be
established between quantity of oil through orifice and quantity of oil going out through
the outlet port even if the pressure of incoming oil changes, the rebalancing will
established automatically and constant flow of oil will come out.

Attempt any FOUR

Compare gear pump and vane pump (Any four points)
3 a
Parameters Gear pump Vane pump
Viscosity Ideal for high viscosity liquids Ideal for low viscosity liquids
Maintenance Easy to maintain Not Easy to maintain
Moving Two moving parts Two moving parts
parts Any four
Construction Simple in construction than vane Complex in construction 1 marks each
pump
Efficiency higher efficiencies Lesser efficiencies
Design Simple designs Complex designs

Define viscosity index and its significance

Viscosity index: It is defined as rate of change of viscosity with respect to temperature.
b Significance: 1 Mark
 It is the most important property which determines the performance of lubricating oils
under operating conditions.
 Viscosity index used to characterize the viscosity-temperature behaviour
of lubricating oils.
 The lower the Viscosity index, the more the viscosity is affected by changes in
3 Marks
temperature.
 On machine part moving at slow speeds under high pressures, a heavy oil should be
used as it better resists being squeezed out from between the rubbing parts light oils
can be used for lower pressures and high speeds.
It is not possible to maintain a liquid oil film between two moving or sliding surfaces if the
viscosity is too low.

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Application of check valve with suitable circuit.
A check valve is the simplest type of directional control valve used
c in hydraulic systems. 1 Mark
Check valves allows flow of fluid in one direction and blocks in opposite direction.
Application of check valve
Meter in circuit, meter out circuit, sequencing circuit, loading and unloading circuits etc.
Figure shows a meter-in circuit with control of extend stroke. The inlet flow into the
cylinder is controlled using a flow-control valve. In the return stroke, however, the fluid 1Mark
can bypass the needle valve and flow through the check valve and hence the return speed
is not controlled. This implies that the extending speed of the cylinder is controlled
whereas the retracing speed is not.

2 Marks
Any circuit with check
valve can be considered

4/3 rotary DC valve

02 Sketches

Connected block
The rotary spool directional control valve has a round core with one or more passages or
recesses in it. The core (rotor) is mounted within a stationary sleeve (casing). As the core 02 Working
is rotated within the stationary sleeve, the passages or recesses connect or block the ports
in the sleeve. The ports in the sleeve are connected to the appropriate lines of the fluid
system.

Comparison of Meter out and bleed off circuit

Parameter Meter out circuit Bleed off circuit

e Use More commonly used less commonly used 4 Points
Flow used Flow is drain to tank an additional line is run through a
1 marks each
flow-control valve back to the tank
speed of the Speed remains constant Speed decreases
actuator
Flow of fluid Constant fluid flow through flow Less fluid through flow control
control valve valve
Page No: ____/ N
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Regenerative Circuit.
Regenerative circuits are used when it is desirable to rapidly advance an actuator into
f position to reduce cycle time. When configured as a regenerative system, cylinders can 2 Marks
be advanced more rapidly than in normal operation with the pump flow rate alone. In
order to accomplish regeneration, the fluid leaving the rod end of the cylinder is routed
back to the cap side of the cylinder to combine with the pump flow rate from the pump as
shown in Figure.

2 Marks

( Single Fig is
expected)

Regenerative circuit ( during extension) Regenerative circuit ( during retraction)

Attempt any TWO

Balance vane pump , explanation with sketch
4 a If a net load on shaft bearings of pump is balanced then the pump is balanced vane pump.
explanation with sketch 1 Mark
A balanced vane pump is a very versatile design . The basic design principle is shown in
Fig. The rotor and vanes are contained within a double eccentric cam ring and there are
two inlet segments and two outlet segments during each revolution. This double pumping 4 Marks
action not only gives a compact design, but also leads to another important advantage:
although pressure forces acting on the rotor in the outlet area are high, the forces at the
two outlet areas are equal and opposite, completely canceling each other.

3 Marks

Quick exhaust valve

A quick exhaust valve is a typical shuttle valve.
b It consist of a movable disc (also called flexible ring) and three ports namely, Supply port
1, which is connected to the output of the final control element (Directional control
valve). The Output port, 2 of this valve is directly fitted on to the working port of Working
cylinder. The exhaust port, 3 is left open to the atmosphere
Forward Motion: During forward movement of piston, compressed air is directly 3 Marks
Page No: ____/ N
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
admitted behind the piston through ports 1 and 2, Port 3 is closed due to the supply
pressure acting on the diaphragm. Port 3 is usually provided with a silencer to minimise
the noise due to exhaust.
Return Motion: During return movement of piston, exhaust air from cylinder is directly
exhausted to atmosphere through opening 3 (usually larger and fitted with silencer). Port
2 is sealed by the diaphragm. Thus exhaust air is not required to pass through long and Fig.
narrow passages in the working line and final control valve.
2 Marks

Symbol

1 Mark

Application of a quick exhaust valve :

They are available in a variety of shapes and sizes and are used in the industry to speed 2 Marks
up the performance of a moving cylinder, evacuate air directly out into the atmosphere
and increase the cylinder rod reaction time, or valve actuator.
High quality quick exhaust valves are the key to efficient functions in the industrial
segments.

Classification of pneumatic actuator

Based on application for which air cylinders are used
c i) Light duty air cylinders
ii) Medium duty air cylinders
iii) Heavy duty air cylinders Classification
2. Based on the cylinder action 3 Marks
i) Single acting cylinder
ii) Double acting cylinder
Single rod type double acting cylinder
Double rod type double acting cylinder
3. Based on cylinder’s movement
i) Rotating type air cylinder
ii) Non rotating type air cylinder

Working of vane type air motor

It consists of simple Vane rotor which is having slots in which vanes (flat piece of steel)
slides freely. The rotor is eccentrically located inside the stator housing. Working: When Working
pressurized air comes in through inlet port, the pressure of air distributes equal in all
directions. Since vane is sliding freely in slots of rotator, the vane comes in to way of 3 Marks
pressurized air and air pushes the vanes so that rotor starts rotating with speed. The used
low pressure air is exhausted through exhaust port. This is unidirectional motor. Since
vanes are freely sliding in slots, there is possibility of leakage of air.

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Sketch

2 Marks

Attempt any FOUR

5 a
Working of bag type accumulator:
This accumulator consists of
a seamless high-pressure shell, Figure
cylindrical in shape, with domed ends
and a synthetic rubber bag that 2 Marks
separates the liquid and gas (usually
nitrogen) within the accumulator. The
bag is fully enclosed in the upper end
of a shell. The gas system contains a
high-pressure gas valve. The bottom
end of the shell is sealed with a special
plug assembly containing a liquid port
and a safety feature that makes it
Working
impossible to disassemble the accumulator with pressure in the system. The bag is larger
at the top and tapers to a smaller diameter at the bottom. As the pump forces liquid into 2 Marks
the accumulator shell, the liquid presses against the bag, reduces its volume, and increases
the pressure, which is then available to do work.

Pressure regulator in pneumatic system

The body of regulator has inlet and outlet port. There are two springs one is light and Working
b other is main spring. The main spring can be compressed by spring adjusting screw. The
diaphragm is attached to main spring. 2 Marks

The high pressure of the compressed air should be regulated to the requirement of the
circuit. When main spring is compressed by adjusting the screw upward the diaphragm
will move upward. This will lift the valve element upward, creating an opening to allow
the air from inlet to outlet.

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
The opening of the valve and pressure flowing through it will be directly proportional to Figure
compression of the main spring.
When spring pressure is less the 2 Marks
amount of opening will be small
and there will be slight pressure
reduction. If spring compression is
more then there will be more
pressure reduction hence regulator
will work like pressure reducing
valve.

Advantages of Pneumatic system

1) Pneumatic system provides cheaper and light weight equipment’s as they work 2 Marks
c
on air which is freely available and no robust construction is required.
2) No return lines are required. Any Four
3) Pneumatic system is fire proof, explosion proof and non-reactive thus a safer
system. Hence can be used in fire prone area.
4) Pneumatic system is clean as air is dry. Hence it is widely used in food
processing, electronic and automation industry
5) Pneumatic system provides cheaper and light weight equipment’s as they work
on air which is freely available and no robust construction is required.
6) No return lines are required.
7) Pneumatic system is fire proof, explosion proof and non-reactive thus a safer
system. Hence can be used in fire prone area.
8) Pneumatic system is clean as air is dry. Hence it is widely used in food
processing, electronic and automation industry

Limitation of Pneumatic System.

1) High cost of compression
2) Reduced accuracy
2 Marks
3) Noisy working
4) High operating cost Any four
5) Low pressure application
6) Additional lubrication required.
7) High cost of compression
8) Reduced accuracy
9) Noisy working
10) High operating cost
11) Low pressure application

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

(i) Twin Pressure valve

1 Marks for
each symbol
d

(ii) FRL Unit

(iii) Silencer

(iv) Shuttle valve

Gear Type Air Motor Diagram

2 Marks
e

It consists of two inter meshing gears inside a housing with one gear attached to the Explanation
drive shaft. Figure shows a schematic diagram of Gear motor. The air enters from the
inlet, causes the rotation of the meshing gear due to difference in the pressure and 2 Marks
produces the torque. The air exists from the exhaust port. Gear motors tend to leak at
low speed, hence are generally used for medium speed applications.

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Circuit Diagram

5 f Diagram
with Label
4 Marks

Attempt any TWO

6 a Figure shows a high low unloading circuit. It consists of two pumps. 1. High pressure,
low flow pump 2. Low pressure, high flow pump.
In punching machine hydraulic ram are Circuit
required to function in following Diagram
manner:
1) It should initially extend rapidly over 3 Marks
a large distance
2) Then during punching operation, it
should extend through a very short
distance with very high pressure.
The circuit shown in figure uloads both
the pumps to drain when the 4/3 way
D.C. valve is in central position. When
4/3 way DCV is shifted to position (1),
during the rapid extension stroke, Working
portion, both the pumps supply fluid to 3 Marks
the system. When the punching
operation begins, the system pressure
rises. The increased pressure opens the
unloading valve for the low pressure
pumps. The check valve protects the low
pressure pump 2 from high pressure
which occurs during the punching operation stage of the extension stroke. The purpose of Application
the relief valve B in to protect the high pressure at the end of the cylinder stroke.
Application: Punching Press, Bench vice,Shaper Machine 2 Marks

When valve 1.2 is manually actuated, pilot operated valve 1.1 is shifted in position 1 which brings
the forward stroke of the DAC A. The end of the forward stroke is sensed by the roller operated
b valve 1.4 which can start the return stroke of the piston by shifting valve 1.1 to 0 position.
However the return stroke is delayed by time delay valve 1.3 by certain time which can be
adjusted. As soon as the signal pressure in the time delay valve reaches the adjusted value of

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
spring force of air operated 3/2 DCV, the valve opens and passes the signal to main pilot operated
DCV 1.1 which resets and cylinder retracts after a particular dwell time.

Symbol
Circuit
Diagram
4 Marks

Applications:
Application
1) Bottle filing system
2 Marks
2) Small component assemblies

Symbol
Symbol
2 Marks

Page No: ____/ N

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Pneumatic circuit for speed control of Circuit
bidirectional motor Diagram
6 c Compressed air is passed through
DCV from port P to port A. it will enter in the 4 Marks
FCV1 where flow area of FCV1 is reduced by
partially closing the valve. Hence small
quantity of air will enter in the air motor
through inlet A. It will rotate the motor at slow
speed.
Similarly when flow area of the
FCV1 is increased by fully opening the valve,
it will supply full quantity of compressed air to Working
the air motor through inlet A. As large
quantity is supplied it will rotate the motor at 4 Marks
high speed. We can control the speed in
another direction using FCV2 and second
position of DC valve.
Hence by varying the flow quantity of air we
can change the flow quantity of air we can change the speed of bi-directional motor.
The check valve of circuit allows flow of air into the motor while regulate the outward
flow hence it is ‘meter out’ circuit

Page No: ____/ N