Design and Development of Automatic Hydraulic Circuit

This is Mechatronics Engineering project report on "design and development of automatic hydraulic circuit for punching operation". A hydraulic press is a machine using a hydraulic cylinder to generate a compressive force. Automated hydraulic punching system is based on the same concept of developing smarter systems. Traditional punching machines require continuous attention and failing which may not only affect the output but can also result in accidents. Automated punching system has an appealing feature which allows the continuous operation without much human intervention with applications of various sensors and modern controls. You can also subscribe to FINAL YEAR PROJECT'S by Email for more such projects and seminar.

The objective is to improve and automate the hydraulic punching system in order to provide a safer and efficient system to the industry. The system designed is itself compatible to perform various other functions as well depending upon the type of application for which it has to be used. As the machine performs its function the worker can focus on other important factors during the operation. In case of any improper or insufficient operation manual resetting switches are provided which make sure that the process is repeated without displacing the part forward on the production line.


The system was developed in two parallel ways. The first method uses sophisticated relay logic for onboard control whereas; the second method was developed for off-board or distant control using a Programmable Logic Controller.

The system consists of two parts:-

a) Hydraulic circuit (which includes pump, valves and hydraulic actuator)
b) Electrical and Electronic system (which includes the various switches and controls).

In case of relay control, an onboard circuit is designed which will control the working of punch whereas; in case of PLC control, a program was generated and loaded in the PLC for performing the motion of actuator at the required instant. Proximity switches are used to sense the part which is to be punched and the extreme extended position of the hydraulic cylinder.

As the proximity switch or sensor senses the part on the conveyor it activates the hydraulic circuit. As the circuit is activated the hydraulic actuator tends to extend. Another proximity switch senses the extreme position of the hydraulic cylinder and prevents the further extension when the required length of stroke is achieved. As soon as the required stroke is achieved the retraction of the cylinder starts which makes the cylinder to achieve its initial position.

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Benefits of automated systems over manual systems

Due to growing competition across the globe, industries are looking for apparatus which not only tends to decrease the production cost but also increases the rate of production without compromising with the quality of the product being manufactured. And that’s the time when automation comes to light. Automation is nothing but replacement of manual efforts by mechanical power. This demands the design and development of optimized electro-mechanical systems that can perform the same manual tasks but in less time and increased efficiency.

Atomization of machines has some of the following benefits over conventional machines:

• To achieve high safety
• To reduce man power
• To increase the efficiency
• To reduce the work load
• To reduce the accidents
• To reduce the fatigue of workers
• To high responsibility
• Less Maintenance cost

Working of Hydraulic Circuit

The working of the so designed system takes place in three steps mentioned as follows:-

• When the sensor B1 senses the object which is to be punched, the hydraulic circuit is activated.

• As the hydraulic circuit is activated the extension of the cylinder takes place. The extension stroke is responsible for the punching operation.

• Depending upon the type of material which is to be punched, the speed of the extension stroke is adjusted accordingly.

• When the sensor B2 senses the extreme position of the cylinder, the further extension stroke is prevented and at the same time. the retraction stroke takes place.


Use this report for your reference and study purpose only. This report contains all the details which you need to make your own project including "Hydraulic circuit for punching operation, PLC ladder logic". Good Luck!

Author:- Joyesh Dutt, Prince Verma, Rohit Rana, Bhupinder Singh, and Abhinandan Singh


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