Basic Hydraulic Circuits -

Analysis
 HYDRAULICS
1. What is hydraulic technology? In the hydraulic
technology we transmit and control forces and velocities
by transmitting and controlling pressure and flow. In
nearly every kind of technology we use hydraulic drive
and control techniques. A few examples are:
• mechanical engineering
• car technology
• agriculture technology
• earthmoving and mining technology
• ship building technology
• offshore-technology
• aircraft and spacecraft technology
CONTROL OF A SINGLE-ACTING HYDRAULIC
CYLINDER

A two-position, three-way, manually

actuated, spring offset directional control
valve (DCV) can be used to control the
operation of a single-acting cylinder. In
the spring offset mode, full pump flow
goes to the tank via the pressure relief
valve. The spring in the rod end of the
cylinder retracts the piston as oil from
the blank end drains back to the tank.
When the valve is manually actuated into
its left envelope flow path configuration,
pump flow extends the cylinder. At full
extension, pump flow goes through the
relief valve. Deactivation of the DCV
allows the cylinder to retract as the DCV
shifts into its spring offset mode.
 CONTROL OF A DOUBLE-ACTING
HYDRAULIC CYLINDER
1.      When
the four-way valve is in its spring-
centered position (tandem design), the
cylinder is hydraulically locked. Also the
pump is unloaded back to the tank.
2.      When the four-way valve is actuated into
the flow path configuration of the left
envelope, the cylinder is extended against its
load force, as oil flows from port P through
port A. Also, oil in the rod end of the cylinder
is free to flow back to the tank via the four-
way valve from port B through port T.   .

When the four-way valve is deactivated, the spring-centered envelope prevails, and the
cylinder is once again hydraulically locked.
4.      When the four-way valve is actuated into the right envelope configuration, the
cylinder retracts as oil flows from port P through port B. Oil in the blank end is returned
to the tank via the flow path from port A to port T.
5.   The check valve prevents the load from retracting the cylinder while it is being
extended
 A regenerative circuit is used to speed up the
extending speed of a double-acting hydraulic cylinder.
 Drilling Machine Application.

1. The spring-centered position gives rapid spindle advance (extension).

2. The left envelope mode gives slow feed (extension) when the drill
starts to cut into the workpiece.
3. The right envelope mode retracts the piston.
Pump-Unloading
The unloading valve opens when the
cylinder reaches the end of its extension
stroke because the check valve keeps
high-pressure oil in the pilot line of the
unloading valve. When the DCV is
shifted to retract the cylinder, the motion
of the piston reduces the pressure in the
pilot line of the unloading valve. This
resets the unloading valve until the
cylinder is fully retracted, at which point
the unloading valve unloads the pump.
Thus, the unloading valve unloads the
pump at the ends of the extending and
retraction strokes as well as in the spring-
centered position of the DCV.
 DOUBLE-PUMP HYDRAULIC SYSTEM

A high-pressure, low-flow pump in conjunction with a low-pressure, high-flow

pump. A typical application is a punch press in which the hydraulic ram must extend
rapidly over a large distance with very low pressure but high flow requirements.
However, during the short motion portion when the punching operation occurs, the
pressure requirements are high due to the punching load. Since the cylinder travel is
small during the punching operation, the flow-rate requirements are also low.
 PRESSURE
INTENSIFIER

An intensifier is a device that makes use of this pressure intensification

phenomenon by using a large piston on the input end and a small piston within
a small-bore cylinder on the output end. These devices can be used where
small quantities of fluid are required at a pressure higher than the normal
system operation.
Pressure intensifier circuit.
 COUNTER-BALANCE VALVE

the use of a counterbalance or back-pressure valve to keep a vertically mounted cylinder

in the upward position while the pump is idling. The counterbalance valve is set to open
at slightly above the pressure required to hold the piston up. This permits the cylinder to
be forced downward when pressure is applied on the top. The open-center directional
control valve unloads the pump.
Hydraulic Cylinder Sequence Circuit ,
 Clamp Drill Sequence Circuit ,

When the solenoid valve is shifted, fluid flows to the blank end of both
cylinders. The clamp cylinder extends first. When the clamp contacts the
workpiece, the pressure rises shifting sequence valve S1 and the drilling
operation begins.
When the solenoid valve reverses the direction of flow, first the drill retracts,
sequence valve S2 is shifted and then the clamp releases the work piece. Notice
AUTOMATIC CYLINDER RECIPROCATING
SYSTEM (Hydraulic Hammer)
 AUTOMATIC CYLINDER RECIPROCATING
SYSTEM (Hydraulic Hammer)

A circuit that produces continuous reciprocation of a

hydraulic cylinder. This is accomplished by using two
sequence valves, each of which senses a stroke
completion by the corresponding buildup of
pressure. Each check valve and corresponding pilot
line prevents shifting of the four-way valve until the
particular stroke of the cylinder has been completed.
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 DCV to shift as required.
AUTOMATIC CYLINDER RECIPROCATING
SYSTEM (Hydraulic Hammer)
 LOCKED CYLINDER
USING PILOT CHECK
VALVES
The cylinder can be extended and
retracted as normally done by the
action of the directional control valve.
If regular check valves were used, the
cylinder could not be extended or
retracted by the action of the DCV.
An external force, acting on the piston
rod, will not move the piston in either
direction because reverse flow
through either pilot check valve is not
permitted under these conditions.
 Synchronization of Cylinders

Cylinders hooked in parallel will not

operate in synchronization.
 Cylinders hooked in parallel will not
operate in synchronization.

However, even if the two cylinders are identical, it would be

necessary for the loads on the cylinders to be identical in order
for them to extend in exact synchronization. If the loads are not
exactly identical (as is always the case), the cylinder with the
smaller load would extend first because it would move at a lower
pressure level. After this cylinder has fully completed its stroke,
the system pressure will increase to the higher level required to
extend the cylinder with the greater load.
It should be pointed out that no two cylinders are really
identical. For example, differences in packing friction will vary
from cylinder to cylinder. This alone would prevent cylinder
synchronization for the circuit
 Cylinders hooked in series will operate
in synchronization.

P1 Ap1 - P2 (Ap1 – AR1) = F1 and P2 Ap2 - P3 (Ap2 – AR2) = F2

  Adding both equations and noting that Ap2 = Ap1 – AR1 and that P3 = 0 (due to
the drain line to the tank), we obtain the desired result:  P1 Ap1 = F1 + F2
Here two double end rod cylinders of equal bore are connected in series.
Fluid from the first cylinder is used to power the second. Variations in
leakage past piston seals will cause variation in stroke between the two
cylinders. Since the deviation is cumulative, the system can be expected
to run out of synchronization after repeated cycling.
 Correction for minor variation in synchronization at the end of
each cycle can be made by using a replenishing circuit to supply
make-up oil for that lost due to leakage.
The circuit uses a four-way, three-position valve to extend and
retract cylinders 1 and 2, which are connected in series.
Solenoid valve A replenishes the circuit.
On extension, if cylinder 1 bottoms first, it contacts a limit
switch energizing solenoid valve A that supplies additional
fluid to fully extend cylinder 2.
On retraction, if cylinder 2 bottoms first, it contacts a limit
switch energizing solenoid valve A that supplies additional
fluid to retract cylinder 1. In this manner, the strokes of both
cylinders can be expected to begin and end when both
cylinders are in the same position.
Synchronous Circuit Using Flow Divider

Another method is to meter an equal amount of fluid to each

circuit by using two fixed displacement fluid motors of equal
volume or a flow divider.
 Using Flow Dividers
The circuit uses a fixed displacement pump to supply fluid to two
cylinders of equal displacement through a flow divider. The
circuit is controlled by a four-way three-position DCV. On
extension, fluid is fed to the flow divider which meters equal
amounts to cylinders 1 and 2 causing them to extend in
synchronization. Centering the control valve locks the cylinders.
Shifting the control valve to retract both cylinders causes fluid to
be fed to the rod ends of each cylinder and the return fluid from
the blank ends of each cylinder to be metered in equal amounts
through the flow divider. While the flow divider meters equal
amounts of fluid in and out of each cylinder, there is no
compensation made for leakage and fluid by-passing the cylinder
pistons.
 Synchronizing fluid power motors

Synchronizing fluid power motors on conveyors and roller feed systems

is critical where slack in the system can affect production quality and
machinery breakdown.
Fluid is supplied to the system from a common manifold to which each fluid
motor is connected. Each fluid motor in turn drives an auxiliary pump
connected in series, and supplies fluid to pilot operate normally open two-way
control valves that connect the fluid supply from the manifold to each
conveyor drive motor. The pilot circuit terminates at the variable-
displacement metering pump that regulates the speed of the system.
When the system is started, pressurized fluid from the manifold is supplied to
conveyor drive motors a and b which drive the auxiliary pumps. Metering
fluid passes through the auxiliary pumps and metering pump. Fluid motor
speed continues to increase until the fluid through the auxiliary pumps and
metering pump are equal.
An increase in speed of either motor causes pressure to build in the circuit
piloting the two-way control valves toward the closed position which reduces
flow from the manifold to the respective motor.
A decrease in speed of either motor causes pressure to be reduced at the
respective auxiliary pump output and the pilot operated control valve opens.
The metering valves in the circuit are used to dampen surges and natural
harmonics generated by the system.
 FAIL-SAFE CIRCUITS

Prevents the cylinder from accidentally falling in the event a hydraulic line
ruptures or a person inadvertently operates the manual override on the pilot-
actuated directional control valve when the pump is not operating.
 FAIL-SAFE CIRCUITS

To lower the cylinder, pilot pressure from the blank end of the
piston must pilot-open the check valve at the rod end to allow
oil to return through the DCV to the tank. This happens when
the push-button valve is actuated to permit pilot pressure
actuation of the DCV or when the DCV is directly manually
actuated while the pump is operating. The pilot-operated DCV
allows free flow in the opposite direction to retract the cylinder
when this DCV returns to its spring offset mode.
Fail-safe circuit with overload
protection.
 Fail-safe circuit with overload
protection.

A fail-safe circuit that provides overload protection for system

components. Directional control valve 1 is controlled by push-
button three-way valve 2. When overload valve 3 is in its spring
offset mode, it drains the pilot line of valve 1. If the cylinder
experiences excessive resistance during the extension stroke,
sequence valve 4 pilot-actuates overload valve 3. This drains the
pilot line of valve 1, causing it to return to its spring offset mode.
If a person then operates push-button valve 2, nothing will
happen unless overload valve 3 is manually shifted into its
blocked port configuration. Thus, the system components are
protected against excessive pressure due to an excessive cylinder
load during its extension stroke.
Two-Hand Safety Circuit.
 Two-Hand Safety Circuit.

For the circuit to function (extend and retract the cylinder), the
operator must depress both manually actuated valves via the push
buttons. Furthermore, the operator cannot circumvent this safety
feature by tying down one of the buttons, because it is necessary
to release both buttons to retract the cylinder. When the two
buttons are depressed, the main three-position directional control
valve is pilot-actuated to extend the cylinder. When both push
buttons are released, the cylinder retracts.
Fail Safe Circuit with Overload Protection
and Interlock
A fail-safe circuit with overload protection and an interlock to protect
operating personnel. The interlock requires that both palm valves be
depressed for the cylinder ram to be retracted. This prevents the
operator from tying one valve down. Thus releasing one hand that
may become injured in the press during the work portion of the cycle.
When the pump is started, fluid initially flows through the four-way
DCV and the pilot circuit is opened. This allows the circuit to warm
up with the pump isolated from the rest of the system.
Opening the pilot shut-off valve sends a pilot signal through both
four-way interlock valves to operate the main control valve retracting
the cylinder. When both four-way palm valves are depressed, the
main control valve is shifted to supply fluid to the blank end of the
cylinder. Releasing both palm valves causes the press ram to be
returned. The fail safe and overload portions of the circuit prevent
accidental dropping of the ram and vent the pilot signal to the main
control valve to return the ram should unanticipated obstruction be
encountered on the downward stroke.
SPEED CONTROL OF A
HYDRAULIC MOTOR
HYDRAULIC MOTOR BRAKING
SYSTEM
Hydrostatic Transmission

Closed-circuit
one-direction
hydrostatic
transmission.
Closed-circuit reversible-direction
hydrostatic transmission.
Packaged unit hydrostatic drive-
reversible direction.
AIR-OVER-OIL CIRCUIT
Compressed air flows through a filter, regulator, lubricator unit
(FRL) and into a surge tank via a directional control valve (upper
flow path configuration). Thus, the surge tank is pressurized by
compressed air. This pushes oil out the bottom of the surge tank
and to the hydraulic cylinder through a check valve and orifice
hooked in parallel.
This extends the cylinder to lift a load. When the directional
control valve is shifted into its lower flow path mode, the
cylinder retracts at a controlled rate. This happens because the
variable orifice provides a controlled return flow of oil as air
leaves the surge tank and exhausts into the atmosphere via the
directional control valve. The load can be stopped at any
intermediate position by the spring-centered position of the
directional control valve. This system eliminates the need for a
costly hydraulic pump and tank unit.
AIR-OVER-OIL INTENSIFIER
SYSTEM
an air-over-oil circuit, which drives a cylinder over a large
distance at low pressure and then over a small distance at high
pressure. Shop air can be used to extend and retract the cylinder
during the low-pressure portion of the cycle. The system operates
as follows: Valve 1 extends and retracts the cylinder using shop air
at 80 psi. Valve 2 applies air pressure to the top end of the
hydraulic intensifier. This produces high hydraulic pressure at the
bottom end of the intensifier.
Actuation of valve 1 directs air to the approach tank. This forces
oil at 80 psi through the bottom of the intensifier to the blank end
of the cylinder. When the cylinder experiences its load, valve 2 is
actuated, which sends air to the top end of the intensifier. The
high-pressure oil cannot return to the approach tank because this
port is blocked off by the downward motion of the intensifier
piston. Thus, the cylinder receives high-pressure oil at the blank
end to overcome the load.
When valve 2 is released, the shop air is blocked, and the top
end of the intensifier is vented to the atmosphere. This
terminates the high-pressure portion of the cycle. When valve 1
is released, the air in the approach tank is vented, and shop air is
directed to the return tank. This delivers oil at shop pressure to
the rod end of the cylinder, causing it to retract. Oil enters the
bottom end of the intensifier and flows back to the approach
tank. This completes the entire cycle.
This type of intensifier is capable of producing output hydraulic
pressures up to 3000 psi.
MECHANICAL-HYDRAULIC
SERVO SYSTEM
Operation is as follows:
1. The input or command signal is the turning of the steering wheel.
2. This moves the valve sleeve, which ports oil to the actuator
(steering cylinder).
3. The piston rod moves the wheels via the steering linkage.
4. The valve spool is attached to the linkage and thus moves with it.
5. When the valve spool has moved far enough, it cuts off oil flow to
the cylinder. This stops the motion of this actuator.
6. Thus, mechanical feedback recenters (nulls) the valve (actually a
servo valve) to stop motion at the desired point as determined by
the position of the steering wheel. Additional motion of the
steering wheel is required to cause further motion of the output
wheels.