Hydraulic Circuits

Introduction
A hydraulic circuit is a group of components including one or more pump,
actuators, valves, piping, and ancillary equipment. It is used for power
transmission and control.

Hydraulic Valve Fxv

Hydraulic
Cylinder

VxI Tx
Electric Hydraulic
Motor Pump

PxQ Tx
Hydraulic
Motor
 Hydraulic Circuits
Single Acting Hydraulic Cylinder Control Circuit
Double Acting Hydraulic Cylinder Control Circuit
Regenerative Cylinder Circuit
Pump Unloading Circuit
Double Pump Circuit
Counterbalance Valve Circuits
Cylinder Sequencing Circuits
Locked Cylinders using Pilot Check Valves
Cylinder Synchronization Circuits
Fail Safe Circuits
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
Single Acting Hydraulic Cylinder Control Circuit
 Single Acting Hydraulic Cylinder Control Circuit
Analysis Objectives

Given:
Load carrying capacity
Extension speed
Retraction speed

What are the objective of design analysis?

Single Acting Hydraulic Cylinder Control Circuit
Analysis Objectives

Pump
Flow rate
Pressure Head
Type
Pressure Relief Valve
Cracking pressure
Full Open pressure
Size
Spring
Stiffness
Initial Compression
 Single Acting Hydraulic Cylinder Control Circuit
Design Optimization

What are the objective of

design optimization?
 Single Acting Cylinder Control Circuit
Design Optimization
Improve efficiency (operating cost)
Reduce size and weight
Increase safety
Reduce cost
Simplify operation
Improve functionality
Allow to stop during stroke
Allow servo control
Increase retraction speed
..
Extend working life
Reduce noise
Improve reliability
Reduce pollution and environmental
effects

Double Acting Cylinder Control Circuit

Extend Hold Retract

 Double Acting Cylinder Control Circuit

Hold Retract
Extend
 Automatic Cylinder Reciprocating System
Two sequence valves sense a 0.00 Bar
0.00 Bar
stroke completion by
corresponding buildup of
pressure. Each check valve and
corresponding pilot line
prevents shifting of the
directional control valve until the
particular stroke of the cylinder
has been completed. 0.00 Bar

The check valves are needed to

allow pilot oil to leave either end
of the DCV while pilot pressure is
applied to the opposite end.
This permits the spool of the
valve to move as required.
Automatic cylinder Reciprocating System
 Flow and pressure analysis in the automatic
reciprocating cylinder
During the extension stroke, the speed of
the piston is determined by the flow rate
out of the pump, and the area of the
blank-end of the piston.
vP Ab Q pump , vP Q pump Ab

Assuming constant piston speed, and

resistive load on the piston, (load resisting
the extension), the pressure on the rod
end of the piston (gauge pressure) is equal
to the pressure loss in the return line
connecting the outlet port to the tank.
pr K pipeQ, laminar flow
pr K pipeQ 2 , turbulent flow

f is the friction factor for the pipe. For fully

For a straight circular pipe, the pipe flow turbulent flow, f is a function of the pipes
coefficient, K pipe is: relative roughness. In the transition region, f is
K pipe 128 L D 4 , laminar flow a function of the relative roughness and Re. It is
K pipe 8 f L 2
D 5 , turbulent flow determined from the Moody diagram.
 Flow and pressure analysis in the automatic
reciprocating cylinder
The pressure on the blank end is
determined by the pressure on the rod
side and the load
pb Ab pr Ar Fload
pb pr Ar Ab Fload Ab
 Double Pump
Hydraulic System
 Double Pump Hydraulic System
A high-pressure, low-flow pump
works in conjunction with a low-
pressure, high-flow pump. A
typical application is a sheet
metal punch where high force
and pressure requirements occur
during a short motion portion of 0.00 Bar

the hydraulic cylinder when the

punching operation occurs.
During the punching operation,
the cylinder travel is small, and
thus the flow-rate requirements
are low. The circuit eliminates Low Flow Pump High Flow Pump
the necessity of having a very 24.00 LPM 630.00 LPM

expensive high pressure, high

flow pump
 Double Pump Hydraulic System
Before the punching operation begins,
the rapid extension of the piston is
provided by both pumps operating at
low pressure outlet (pressure is
determined by the load). The flow of
the high-flow pump goes through the
0.00 Bar
check valve to the hydraulic cylinder.
Near the end of the cylinder stroke
the punching operation begins and
the increased pressure opens the
unloading valve to unload the high-
flow pump. The check valve protects Low Flow Pump High Flow Pump

this pump from the high pressure 24.00 LPM 630.00 LPM

generated by the high-pressure pump.

 Analysis of a Double Pump Circuit
The gauge pressure on the rod end
of the piston is equal to the pressure pb Ab pr Ar Fload
loss in the return line connecting the pb pr Ar Ab Fload Ab 0.00 Bar

outlet port to the tank.

pr ,ext K pipeQ, laminar flow
pr ,ext K pipeQ 2 , turbulent flow
Low Flow Pump High Flow Pump
24.00 LPM 630.00 LPM

During the rapid extension, the flow

rate is high and the rod-end pressure
will be significant. The blank-end
During the punching operation, the flow
rate is small, and the rod-end pressure is
pressure, pb,ext is given by:
negligible. The blank-end pressure is
pb ,ext pr ,ext Ar Ab
determined by the punching load:
The pressure calculated above may pb , punch Fpunch Ab
be used to determine the settings of
the unloading valve, ps,uv . For
The pressure calculated above may be used
to determine the settings of the pressure
example, we could set it to be equal
relief valve, ps,rv . For example, we could set
to 1.5 times pb,ext
it to be equal to 1.5 times pb,punxh
Fail-Safe Circuits
Protection from Inadvertent Cylinder Extension
The circuit utilizes a pilot operated check valve to prevent the cylinder
from falling in the event of hydraulic line rupture or pump failure. The
valve also provides protection in case someone inadvertently operates the
manual override on the pilot actuated directional control valve when the
pump is not operating.
Protection from Inadvertent Cylinder Extension
This design also allows the upper directional control valve to be placed at
a distant location from the machine. The lines connected to the valve are
basically for sensing. Flow and pressure (high power lines) go though the
bottom DCV, which acts in a manner similar to relay.
Protection from Inadvertent Cylinder Extension
This design also allows the upper directional control valve to be placed at
a distant location from the machine. The lines connected to the valve are
basically for sensing. Flow and pressure (high power lines) go though the
bottom DCV, which acts in a manner similar to relay.
 Fail Safe with Overload Protection
Directional Control Valve 1 is Sequence
controlled by the pushbutton, Valve
three-way DCV2. If the cylinder
DCV 3
experiences excessive
resistance during its extension
stroke, the sequence valve pilot
actuates the overload DCV 3.
This drains the pilot line of DCV 2
DCV1, causing it to return to its
spring-offset mode. If an
operator then tries to push DCV
2, nothing happens unless
DCV3 is manually shifted to its
DCV 1
blocked port configuration.
Thus the system components
are protected from excessive
load during the extension
stroke.
 Two-Handed Safety System
For the circuit to
extend, the operator
must depress both
manually actuated
valves via the push
button.
When the two
buttons are
depressed, the main
DCV is pilot-
actuated to extend
the cylinder. When
one of the
pushbuttons is
released, the
cylinder retracts.
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System