Lesson Plan
Course Title: Manufacturing Engineering
Session Title: Hydraulic and Pneumatic Systems
Performance Objective:
After completing this lesson, students will be able to recall the principles of hydraulic and
pneumatic systems in a manufacturing process by answering the questions on the Hydraulic
and Pneumatic Systems Worksheet to the teacher’s satisfaction.
Specific Objectives:
 Discuss the purpose of hydraulic and pneumatic systems.
 Research and discuss terms used in typical hydraulic and pneumatic systems.
 Discuss operational principles of typical hydraulic and pneumatic systems
schematics.
 Describe the basic principle of Pascal’s law.
 Recall why it is important to keep hydraulic and pneumatic systems free of leaks.
 List three similarities between hydraulic and pneumatic systems.
 Identify two advantages pneumatic systems have over hydraulic systems.
 List an advantage of hydraulic systems over pneumatic systems.
 Name what step must be taken before disconnecting lines on either system for
maintenance.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the
activities may result in the elimination of any or all of the TEKS listed.
Manufacturing Engineering:

130.329(c)(7)(A)(B)
...use pneumatics devices;
...use hydraulics devices;
Interdisciplinary Correlations:
Physics:
 112.39(c)(2)(A)(B)(C)(D)
...know the definition of science and understand that it has limitations, as specified in
subsection (b)(2) of this section;
...know that scientific hypotheses are tentative and testable statements that must be
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1
capable of being supported or not supported by observational evidence. Hypotheses
of
durable explanatory power which have been tested over a wide variety of conditions
are
incorporated into theories;
...know that scientific theories are based on natural and physical phenomena and are
capable of being tested by multiple independent researchers. Unlike hypotheses,
scientific theories are well-established and highly-reliable explanations, but may be
subject to change as new areas of science and new technologies are developed;
...distinguish between scientific hypotheses and scientific theories;
 112.39(c)(3)(D)
...explain the impacts of the scientific contributions of a variety of historical and
contemporary scientists on scientific thought and society;
English Language Arts and Reading, English I:

110.31(b)(1)(E)
...use a dictionary, a glossary, or a thesaurus (printed or electronic) to determine or
confirm the meanings of words and phrases...

110.31(b)(12) - Reading/Media Literacy.

110.31(b)(19) - Oral and Written Conventions/Spelling.

110.31(b)(24)(A)
…listen responsively to a speaker by taking notes that summarize, synthesize, or
highlight the speaker's ideas for critical reflection and by asking questions related to the
content for clarification and elaboration;

110.31(b)(25) - Listening and Speaking/Speaking.
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Occupational Correlation: (reference: O*Net – www.onetonline.org)
Industrial Machinery Mechanics 49-9041.00
Similar Job Titles: Maintenance Mechanic, Maintenance Technician, Mechanic,
Engineering Technician, Master Mechanic, Industrial Machinery Mechanic
Tasks:









Disassemble machinery or equipment to remove parts and make repairs.
Repair or replace broken or malfunctioning components of machinery or equipment.
Examine parts for defects, such as breakage or excessive wear.
Reassemble equipment after completion of inspections, testing, or repairs.
Observe and test the operation of machinery or equipment to diagnose malfunctions,
using voltmeters or other testing devices.
Operate newly repaired machinery or equipment to verify the adequacy of repairs.
Clean, lubricate, or adjust parts, equipment, or machinery.
Analyze test results, machine error messages, or information obtained from operators to
diagnose equipment problems.
Record repairs and maintenance performed.
Soft Skills:
Critical thinking; Operation monitoring; Judgment and decision making
Teacher Preparation:
Teacher should review the Hydraulic and Pneumatic Systems presentation and notes, Matching
Terms and Definitions handout, and Hydraulic and Pneumatic Systems Worksheet. Teachers
are also encouraged to conduct their own research on lesson material. Locate images of
common hydraulic and pneumatic equipment such as bulldozers, forklifts, jackhammers, dental
drills, photo examples of manual labor from early in the 20th century; and modern hydraulic and
pneumatic equipment to show students during the presentation.
References:
1. O*Net – www.onetonline.org
2. OSHA Safety Hazard Information Bulletin on Hydraulic Systems Preventive
Maintenance, https://www.osha.gov/dts/hib/hib_data/hib19920714.html, (1992).
3. Safeguarding Equipment and Protecting Workers from Amputations,
http://www.osha.gov/Publications/OSHA3170/osha3170.html, (2001).
4. Construction Safety and Health: Hand and Power Tools,
http://www.osha.gov/doc/outreachtraining/htmlfiles/tools.html, (1996).
5. Hydraulic Presses, http://www.sme.org/Wiki.aspx?id=61792&terms=hydraulic, (2012).
6. Hydraulic Presses, http://www.sme.org/Wiki.aspx?id=61792&terms=pneumatic, (2012).
Copyright © Texas Education Agency, 2012. All rights reserved.
3
Instructional Aids:
1. Hydraulic and Pneumatic Systems presentation and notes
2. Matching Terms and Definitions handout and answer key
3. Hydraulic and Pneumatic Systems worksheet and answer key
4. Warm-up activity (slide 3)
Materials Needed:
1. Matching Terms and Definitions handout for each student
2. Hydraulic and pneumatic worksheet for each student
3. Pen or pencil
4. Paper
Equipment Needed:
1. Computer
2. Internet access (optional)
3. Overhead projector
Learner Preparation:
Students must have basic computer skills.
Introduction
Introduction (LSI Quadrant I):
SAY: Having an understanding of hydraulic and pneumatic systems will greatly contribute to
your career success.
ASK: Have you ever thought about how important hydraulic and pneumatic energy is to your
everyday life?
SHOW: Images of common hydraulic and pneumatic equipment: elevators, automobile brakes,
earth moving equipment, roller coasters.
SAY: Hydraulic and pneumatic devices removed much of the manual labor from our daily lives.
ASK: Have you ever talked to a senior citizen about the amount of manual labor they
were required to do when they were young?
SHOW: Photos examples of manual labor from early in the 20th century; and modern
hydraulic and pneumatic equipment.
Outline
Outline (LSI Quadrant II):
Instructors can use the presentation, slides, handouts, and note pages in conjunction with the
following outline.
MI
Outline
Notes to Instructor
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I. Introduction and Start of Lesson
Begin Hydraulic and
Pneumatic Systems
presentation.
Bell Work Activity: have
students work on the Bell
Work Activity.
Slide 2
Warm-up Activity: Using the
Matching Terms and
Definitions handout, students
will pair-share and teach each
other the terms and
definitions. They may do
computer-based research to
look up the meaning.
Slide 3
II. Hydraulic and Pneumatic Systems
A.
Historical overview
B.
21st century advancements
Discuss the importance of
hydraulic and pneumatic
systems and how the
development of these
systems have impacted the
safety and efficiency of labor
in our lives.
Slides 4-5
III. Hydraulic Systems
A. Pascal’s Law
B. Typical system schematic
Discuss the principles of
hydraulic systems including
Pascal’s law, the schematic
diagram and system
components.
Slides 6-7
IIII. Pneumatic Systems
A. Pneumatic system principles
B. Typical system schematic
Discuss the principles of
pneumatic systems including
the schematic diagram and
system components.
Review the notes provided in
the Hydraulic and Pneumatic
Systems presentation and
study background information.
Ensure students understand
how the system operates.
.
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Have some background
knowledge, and challenge the
students to make some
contributions to the
discussion.
Slides 8-9
Each slide is meant to be
discussed.
V. Hydraulic and Pneumatic
Systems Worksheet
A. Assign worksheet
B. Teacher will go over
worksheet in class
Verbal
Linguistic
Logical
Mathematical
Visual
Spatial
Musical
Rhythmic
Bodily
Kinesthetic
Intrapersonal
Distribute and assign the
Hydraulic and Pneumatic
Systems Worksheet to the
students. Teacher will go
over the answers in class for
better understanding.
Interpersonal
Naturalist
Existentialist
Application
Guided Practice (LSI Quadrant III):
Using Matching Terms and Definitions handout, students will pair-share and teach each other
the terms and definitions. They may do computer-based research to look up the meaning.
Independent Practice (LSI Quadrant III):
Students will complete Warm-up Activity, doing computer-based research to look up and match
the meaning of words on the handout, writing out definitions on a sheet of paper. Students will
complete the Hydraulic and Pneumatic Systems Worksheet.
Summary
Review (LSI Quadrants I and IV):
Question: Why are hydraulic and pneumatic systems necessary?
Answer: Hydraulic and pneumatic systems are necessary to accomplish heavy, complex
labor processes. These processes are vital to our society. They save time and
allow products to be produced faster and reduces manual labor.
Question: Identify equipment that depends on hydraulic and pneumatic systems.
Answer: Earth moving and agriculture equipment, hospital and dental equipment,
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automotive and aircraft brakes and steering systems.
Question: What is necessary to become a good at maintaining hydraulic and pneumatic
systems?
Answer: A high level of understanding of system operations.
Evaluation
Informal Assessment (LSI Quadrant III):
Oral question/answer. Students will complete definitions teacher has on the board from terms in
the definitions handout. Students will complete the Hydraulic and Pneumatic Systems
Worksheet and will go over it in class with the teacher.
Formal Assessment (LSI Quadrant III, IV):
No formal assessment in this lesson.
Extension
Extension/Enrichment (LSI Quadrant IV):
1. Students can work in groups to find equipment schematics of other hydraulic and
pneumatic systems; study them and discuss the operations within the group.
2. Students can conduct research and identify a nearby manufacturing facility, then contact
the maintenance supervisor and request a tour of the facility to find out more about how
other hydraulic and pneumatic systems are maintained. If allowed they can take photos
and conduct interviews and create a presentation for class.
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Name______________________________Date_________________Class_________
Manufacturing Engineering
Hydraulic and Pneumatic Systems
Matching Terms and Definitions
Directions: Match the terms in Section 1 with the definitions in Section 2.
Section 1:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Actuators
Pump
Compressor
Gauges
Pressure relief valves
Control valve
Filter
Reservoir
Hydraulic fluid
Tubes / hoses
K. Fittings / connections
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Section 2:
________ used to direct fluid to the proper component, like an actuator, gauge,
output line, etc.
________a key component in a pneumatic system and is used to pressurize air for
transport through the system
________converts the hydraulic pressure (energy) to mechanical energy to
operate the load; (cylinder) - converts hydraulic energy to linear energy to
operate piston rods; (hydraulic motor) - converts hydraulic energy to rotational
energy to rotate a shaft
________provides an analog or digital indication of system pressure
________placed in specific locations in a hydraulic system to relieve excess
pressure to prevent system overload, which would result in leaks, and damaged
components, etc.
________stainless steel or rubber connecting lines that connect system
components and are used for fluid transfer
________provides a pressurized fluid supply to the hydraulic system to operate
the actuators; pressure may be 5000 pounds per square inch (psi), or more
________a critical component used to trap particles (usually metal or dirt) that
could clog and damage system components
________liquid used to circulate through a hydraulic system to transfer energy
between components and to the load; the fluid provides cooling and transfers
particles (contaminants) to the filter
________threaded or clamped connections that are used to connect the tubes
and hoses to system components; must be of proper size and orientation to
prevent leaks
________serves as a storage container for hydraulic fluid
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Manufacturing Engineering
Hydraulic and Pneumatic Systems
Matching Terms and Definitions Answer Key
F. Control valve: used to direct fluid to the proper component, like an actuator,
gauge, output line, etc.
C. Compressor: a key component in a pneumatic system and is used to pressurize
air for transport through the system
A. Actuators: converts the hydraulic pressure (energy) to mechanical energy to
operate the load; (cylinder) - converts hydraulic energy to linear energy to
operate piston rods; (hydraulic motor) - converts hydraulic energy to rotational
energy to rotate a shaft
D. Gauges: provides an analog or digital indication of system pressure
E. Pressure relief valves: placed in specific locations in a hydraulic system to
relieve excess pressure to prevent system overload, which would result in leaks,
damaged components, etc.
J. Tubes / Hoses: stainless steel or rubber connecting lines that connect system
components and are used for fluid transfer
B. Pump: provides a pressurized fluid supply to the hydraulic system to operate
the actuators; pressure may be 5000 pounds per square inch (psi), or more
G. Filter: a critical component used to trap particles (usually metal or dirt) that
could clog and damage system components
I. Hydraulic fluid: liquid used to circulate through a hydraulic system to transfer
energy between components and to the load; the fluid provides cooling and
transfers particles (contaminants) to the filter
K. Fittings / connections: threaded or clamped connections that are used to
connect the tubes and hoses to system components; must be of proper size and
orientation to prevent leaks
H. Reservoir: serves as a storage container for hydraulic fluid
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Name______________________________Date_________________Class_________
Manufacturing Engineering
Hydraulic and Pneumatic Systems Worksheet
Directions: Answer the six questions below.
1. Describe the basic principle of Pascal’s law.
2. Why is it important to keep hydraulic and pneumatic systems free of leaks?
3. List three similarities between hydraulic and pneumatic systems.
4. Identify two advantages pneumatic systems have over hydraulic systems.
5. List an advantage of hydraulic systems over pneumatic systems.
6. What step must be taken before disconnecting lines on either system for
maintenance?
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11
Manufacturing Engineering
Hydraulic and Pneumatic Systems Worksheet
Worksheet Answer Key
1. Describe the basic principle of Pascal’s law.
Answer: Liquid cannot be compressed. When pressure is applied
to liquid in a confined space, equal force is transmitted throughout
the entire system.
2. Why is it important to keep hydraulic and pneumatic systems free of leaks?
Answer: The system may be under several thousand pounds of
pressure. Leaks can be dangerous and cause severe personal
injury by puncturing skin and vital organs.
3. List three similarities between hydraulic and pneumatic systems.
Answer: both systems use a pressurized liquid medium, both
systems have lines, valves, and actuators
4. Identify two advantages pneumatic systems have over hydraulic systems.
Answer: 1. Lower pressure (usually less than 300 psi), no chance
of fluid spills or product contamination; 2. Pressurized air can be
stored for later use if power is not available from the compressor.
5. List an advantage of hydraulic systems over pneumatic systems.
Answer: Hydraulic systems are very stable under load and can
carry very high load capacities.
6. What step must be taken before disconnecting lines on either system for
maintenance?
Answer: Relieve all system pressure before disconnecting lines.
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