Festo Hydraulics Workbook Basic Level TP501 204

Learning System for Automation
Hydraulics
Workbook Basic Level
094468 (04/01)
Authorised applications and liability
The Learning System for Automation and Communication has been de-
veloped and prepared exclusively for training in the field of automation
and communication. The training organization and / or trainee shall en-
sure that the safety precautions described in the accompanying Techni-
cal documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation, un-
less caused by premeditation or gross negligence on the part of Festo
Didactic.
Order no.: 094468

Description: TEACHW. HYDRAUL.
Designation: D.S501-C-SIBU-GB
Edition: 04/01
Layout: 30.04.2001, OCKER Ingenieurbüro
Graphics: OCKER Ingenieurbüro
Author: D. Waller, H. Werner
© Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2001

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
Parts of this training documentation may be duplicated, solely for train-
ing purposes, by persons authorised in this sense.
TP501 · Festo Didactic

3
Preface
Festo Didactic’s Learning System for Automation and Communications
is designed to meet a number of different training and vocational re-
quirements. The Festo Training Packages are structured accordingly:
Basic Packages provide fundamental knowledge on a wide range of
technologies.
Technology Packages deal with important areas of open-loop and
closed-loop control technology.
Function Packages explain the basic functions of automation sys-
tems.
Application Packages provide basic and further training closely ori-
ented to everyday industrial practice.
Technology Packages deal with the technologies of pneumatics, elec-
tropneumatics, programmable logic controllers, automation with PCs,
hydraulics, electrohydraulics, proportional hydraulics and application
technology (handling).
Mounting frame Fig. 1:

Hydraulics 2000 –
i.e. mobile workstation
U = 230V~
Profile plate
p = 6 MPa
Storage tray
TP501 • Festo Didactic

4
The modular structure of the Learning System permits applications to be

assembled which go beyond the scope of the individual packages. It is
possible, for example, to use PLCs to control pneumatic, hydraulic and
electrical actuators.
All training packages have an identical structure:
Hardware
Courseware
Software
Courses
The hardware consists of industrial components and installations,

adapted for didactic purposes.
The courseware is matched methodologically and didactically to the
training hardware. The courseware comprises:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, explanatory notes, solutions and
data sheets)
OHP transparencies and videos (to bring teaching to life)
Teaching and learning media are available in several languages. They
have been designed for use in classroom teaching but can also be used
for self-study purposes.
In the software field, computer-based training programs and program-
ming software for programmable logic controllers are available.
Festo Didactic’s range of products for basic and further training is com-
pleted by a comprehensive selection of courses matched to the contents
of the technology packages.

5
Latest information about the technology package TP501.
New in Hydraulic 2000:

Industrial components on the profile plate.
Exercises with exercise sheets and solutions, leading questions.
Fostering of key qualifications:
Technical competence, personal competence and social competence
form professional competence.
Training of team skills, willingness to co-operate, willingness to learn,
independence and organisational skills.
Aim – Professional competence
Content
Part A Course Exercises
Part B Fundamentals Reference to the text book
Part C Solutions Function diagrams, circuits, descriptions of
solutions and quipment lists
Part D Appendix Storage tray, mounting technology
and datasheets

6

7
Table of contents
Introduction 11
Notes on safety 13
Notes on operation 13
Technical notes 14
Training contents 17
Equipment set for “Hydraulics Basic Level” 19
Component / exercise table for TP 501 24
Section A – Course
Exercise 1: Automatic lathe
Pump characteristic A-3
Exercise 2: Package lifting device
Pressure relief valve characteristic A-7
Exercise 3: Drawing press
Hydraulic resistances A-11
Exercise 4: Calender feeding device
Single-acting cylinder (basic circuit) A-15
Exercise 5: Hardening furnace
Single-acting cylinder
(measurement and calculation) A-19
Exercise 6: Furnace door control
Double-acting cylinder A-23
Exercise 7: Conveyor tensioning device
4/3-way valve with bypass to pump A-29
Exercise 8: Cold-store door
Accumulator A-33
Exercise 9: Rotary machining station
Flow control valve and counter-holding A-37
Exercise 10: Painting booth
Flow control valve characteristic A-41

8
Exercise 11: Embossing machine

One-way flow control valve and counter-holding A-45
Exercise 12: Surface grinding machine
Differential circuit A-49
Exercise 13: Drilling machine
Pressure regulator A-55
Exercise 14: Bulkhead door
Hydraulic clamping of a cylinder A-59
Exercise 15: Ferry loading ramp
Flow control valve in inlet and outlet lines A-63
Exercise 16: Skip handling
Varying load A-69
Exercise 17: Bonding press
Comparison of pressure regulator and –
pressure relief valve A-73
Exercise 18: Assembly device
Pressure sequence circuit,
displacement-step diagram A-77
Calculation of pressure and time A-81
Exercise 20: Tipping container
Electrohydraulics A-85
Section B - Fundamentals

9
Section C – Solutions
Solution 1: Automatic lathe C-3
Solution 2: Package lifting device C-7
Solution 3: Drawing press C-11
Solution 4: Calender feeding device C-15
Solution 5: Hardening furnace C-19
Solution 6: Furnace door control C-23
Solution 7: Conveyor tensioning device C-27
Solution 8: Cold-store door C-33
Solution 9: Rotary machining station C-37
Solution 10: Painting booth C-41
Solution 11: Embossing machine C-45
Solution 12: Surface grinding machine C-49
Solution 13: Drilling machine C-59
Solution 14: Bulkhead door C-65
Solution 15: Ferry loading ramp C-69
Solution 16: Skip handling C-73
Solution 17: Bonding press C-77
Solution 18: Assembly device C-79
Solution 19: Calculation for an assembly device C-83
Solution 20: Tipping container C-85
Section D – Appendix
Storage tray D-3
Mounting systems D-4
Sub-base D-6
Coupling system D-7
Data sheets ...

10

11
Introduction
This workbook forms part of Festo Didactic’s Learning System for
Automation and Communications. The Technology Package “Hydrau-
lics”, TP500, is designed to provide an introduction to the fundamentals
of hydraulic control technology. This package comprises a basic level
and an advanced level. The basic level package TP501 teaches basic
knowledge of hydraulic control technology, while the advance level
package TP502 builds on this.
The basic level hydraulic exercises are designed to be carried out with
manual actuation. It is, however, also possible to use electrical actua-
tion. The hydraulic components have been designed to provide the fol-
lowing:
Easy handling
Secure mounting
Environmentally-friendly coupling system
Compact component dimensions
Authentic measuring methods
We recommend the following for the practical execution of the exer-

cises:
Hydraulic components: Equipment set TP501
One hydraulic power pack
A number of hose lines
A profile plate or a suitable laboratory trolley
A measuring set with the appropriate sensors

12
This workbook provides knowledge of the physical interrelationships and

the most important basic circuits in hydraulics. The exercises deal with
the following:
Plotting of characteristics for individual components
Comparison of the use of different components
Assembly of various basic circuits
Use of basic hydraulics equations
The following technical equipment is required for safe operation of the

components:
A hydraulic power pack providing an operating pressure of 60 bar
and a flow rate of 2 l/min
An electrical power supply of 230V AC for the hydraulic power pack
A power supply unit with an output of 24V DC for solenoid-actuated
valves
A Festo Didactic profile plate for mounting the components
The theoretical background is described in the “Hydraulics Basic Level”

textbook TP501. Technical descriptions of the components used are
given in the data sheets in Part D of this workbook.
Festo Didactic offers the following further training material for hydraulics:
Magnetic symbols
Hydraulics slide rule
Set of OHP transparencies
Transparent models
Interactive video
Symbol library

13
Notes on safety
Observe the following in the interests of your own safety:
Exercise care when switching on the hydraulic power pack. Cylinders
may advance unexpectedly!
Do not exceed the maximum permissible operating pressure (see
data sheets).
Observe all general safety instructions (DIN 58126 and VDE 100).
Notes on operation
Always work in the following sequence when assembling a hydraulic
circuit.
1. The hydraulic power pack and electrical power supply must be

switched off during the assembly of the circuit.
2. All components must be securely fitted to the profile plate, i.e. se-
curely snap-fitted or bolted down.
3. Check that all return lines are connected and all hose lines are se-
curely fitted.
4. Switch on the electrical power supply first and then the hydraulic
power pack.
5. Before dismantling the circuit, ensure that pressure in hydraulic com-

ponents has been released:
Couplings must be connected and disconnected only under

zero pressure!
6. Switch off the hydraulic power pack first and then the electrical
power supply.

14
Technical notes
Observe the following in order to ensure safe operation.
The hydraulic power pack PN 152962 incorporates an adjustable
pressure relief valve. In the interests of safety, the pressure is limited
to approx. 60 bar (6 MPa).
The maximum permissible pressure for all hydraulic components is
120 bar (12 MPa).
The operating pressure should not exceed 60 bar (6 MPa).
In the case of double-acting cylinders, the pressure intensification

effect may produce an increased pressure proportional to the area
ratio of the cylinder. With an area ratio of 1:1.7 and an operating
pressure of 60 bar (6 MPa), this increased pressure may be over
100 bar (10 MPa)!
Fig. 2:
Pressure intensification
If connections are detached under pressure, the non-return valve in

the coupling may cause pressure to become trapped in the valve or
other component concerned. The pressure relieving device PN
152971 can be used to release this pressure. Exception: This is not
possible in the case of hose lines and non-return valves.
All valves, other components and hose lines are fitted with self-
closing quick-release couplings. This prevents the accidental spillage
of hydraulic fluid. In the interests of simplicity, these couplings are not
shown in circuit diagrams.
Fig. 3:
Simplified drawing of
self-closing couplings
Throttle valve Hose Shut-off valve

15
It is frequently necessary when assembling a control circuit to modify

the given circuit diagram. Within the scope of the equipment set in
this Training Package, the following alternative solutions are possible:
Plugs can be used to change the function of directional control valves
(Figs. 4 and 5).
Directional control valves with different normal positions can be used
(Fig. 6).
Solenoid-actuated valves can be used in place of hand lever valves
(Fig. 7).
2/2-way valve 3/2-way valve Fig. 4:

Circuit diagram
4/2-way valve 4/2-way valve Fig. 5:

Practical assembly
Circuit diagram Practical assembly Fig. 6:

Directional control valves
with various
normal positions
Fig. 7:
Solenoid-actuated
directional control valve

16
Flow rate sensor
The flow rate sensor consists of:

A hydraulic motor, which converts the flow rate q into a rotary speed
n.
A tachogenerator, which produces a voltage V proportional to the
rotary speed n.
A universal display unit, which converts the flow rate q into l/min. The
universal display should be set to sensor no. 3 for this purpose.
Fig. 8: q Hydraulic n Tacho- V Universal q

Block circuit diagram motor generator display
Fig. 9:
Circuit diagrams,
hydraulic and electrical
Fig. 10:
Connecting up the
universal display
Battery operation
External power supply

17
Training contents
Characteristics of valves and other components.
Uses of individual valves and other components.
Comparison of uses and functions of different valves and other com-
ponents.
Measurement of variables such as pressure, flow rate and time.
Control of pressure and speed.
Calculations of area ratios, forces, power and speed.
Basic physical principles of hydraulics.
Use of basic hydraulics equations.
Understanding and drafting of circuit diagrams.
Drafting of displacement/step diagrams.
Use of symbols in accordance with DIN/ISO 1219.
Assembly and commissioning of control circuits, including fault-
finding.
Assessment of energy consumption.
Basic hydraulic circuits such as a pressure sequence circuit, a by-
pass circuit to the pump, a differential circuit, circuits with flow control
valves in the inlet, outlet and bypass, circuits with counter-holding
and bypass circuits with a non-return valve.

18
List of training aims Exercise Training aims
1 Drawing a pump characteristic.

2 Drawing a characteristic for a pressure relief valve.
3 Measuring flow resistances.
4 Application of a non-return valve.
Use of a 2/2-way valve to control a single-acting cylinder.
5 Application of a 3/2-way valve.
Determination of times
Determination of times
Use of a pilot-operated non-return valve.
8 Use of a hydraulic accumulator as a power source.
Use of accumulator to power advance and return strokes of cylinder after
pump is switched off.
9 Application of a 2-way flow control valve.
Assembly of a counter-pressure circuit.
10 Plotting of characteristic for a 2-way flow control valve.
Comparison between this valve and a throttle valve.
11 Application of a one-way flow control valve.
Difference between flow control valve and throttle valve on the basis of a
concrete application.
12 Design and mode of operation of a differential circuit.
Influence of piston areas on pressures
13 Design of a control circuit with reduced output pressure.
Explanation of mode of operation of a 3-way pressure regulator.
14 Hydraulic clamping with a double-acting cylinder.
Comparison of circuits with and without counter-holding.
15 Speed control circuit with tractive load.
Comparison of circuits with flow control valves in the inlet line and outlet
line respectively.
16 Circuit for a double-acting cylinder with a varying load.
17 Specification of pressure for a double-acting cylinder.
Choice of either a pressure relief valve or a pressure regulator
18 Pressure sequence circuit.
Drawing of a displacement/step diagram
19 Calculation of forces associated with a double-acting cylinder
Calculation of advance-stroke time of a cylinder piston.
20 Electrohydraulic control circuit.

19
Equipment set for “Hydraulics Basic Level”

Description Order No. Qty. TP501, PN 080246
Pressure gauge 152841 3
Throttle valve 152842 1
One-way flow control valve 152843 1
Shut-off valve 152844 1
Non-return valve, opening pressure 1 bar 152845 1
Non-return valve, opening pressure 5 bar 152846 1
Branch tee 152847 7
Pressure relief valve 152848 1
Pressure relief valve, piloted 152849 1
Pressure regulator 152850 1
Flow control valve 152851 1
Non-return valve, hydraulically piloted 152852 1
Double-acting cylinder 152857 1
Hydraulic motor 152858 1
Diaphragm accumulator 152859 1
Loading weight, 9 kg 152972 1
4/2-way hand lever valve 152974 1
4/3-way hand lever valve, recirculation mid-position 152977 1

20
Additional equipment Description Order No. Qty.
Stop-watch 151504 1
4/3-way hand lever valve, closed in mid-position 152975 1
4/3-way hand lever valve, relieving mid-position 152976 1
Relay, 3-fold 162241 1
Signal input unit, electrical 162242 1
Flow-rate sensor 183736 1
4/2-way solenoid valve 167082 1
4/3-way solenoid valve, closed in mid-position 167083 1
4/3-way solenoid valve, relieving mid-position 167084 1
4/3-way solenoid valve, recirculating mid-position 167085 1
Universal display 183737 1
Pressure sensor 184133 1
Accessories Description Order No. Qty.
Profile plate, large 159411 1

Schlauchleitung, 600 mm 152960 12
Hydraulik-Aggregat 152962 1
Hose line, 1000 mm 152970 4
Pressure relieving device 152971 1
Protective cover (for weight, 9kg) 152973 1
Power supply unit, 24 V, 4.5 A 162417 1
Cable set with safety plugs 167091 1

21
Description Symbol Symbols for

Pressure gauge
equipment set TP501
Throttle valve
One-way flow control valve
Shut-off valve
Non-return valve
Branch tee
Pressure relief valve
Pilot-operated pressure relief valve
Pressure regulator
Flow control valve
Piloted non-return valve
Double-acting cylinder

22
Symbols for Description Symbol

equipment set TP501 Hydraulic motor
Diaphragm accumulator, detailed
Diaphragm accumulator, simplified
Weight
4/2-way hand lever valve
4/2-way solenoid valve
4/3-way hand lever valve, closed in mid-position
4/3-way hand lever valve, relieving mid-position
4/3-Wege-Handhebelventil mit Umlaufstellung

23
Description Symbol Symbols for

4/3-way solenoid valve, closed in mid-position
equipment set TP501
4/3-way solenoid valve, relieving mid position
4/3-way solenoid valve, recirculating mid-position
Hose line
Hydraulic-power pack, detailed
Hydraulic power pack, simplified
Pressure sensor
Flow rate sensor
Hydraulic motor with tachogenerator

24
Component / exercise table for TP 501

Exercises
Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Pressure gauge 1 1 3 1 3 1 1 2 5 3 5 3 4 3 3 3 3 2
Throttle valve 1 1
One-way flow control valve 1 1 1 1
Shut-off valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Non-return valve, 1 bar 1 1 1 1 1 1 1 1
Non-return valve, 5 bar 1 1 1 1 1 1
Branch tee 2 3 4 3 2 3 3 6 2 4 4 5 4 4 4 5 7 2
Pressure relief valve *) 1 2 1 1 1 1 1 2 2 2 1 1 2 2 3 2 3 1
Pressure relief valve, piloted (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)
Pressure regulator 1 1
Flow control valve 1 1 1 1 1 1
Piloted non-return valve 1 1
Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Hydraulic motor 1
Diaphragm accumulator 1
Weight 1 1 1 1
4/2-way hand lever valve 1 1 1 1 1 1 1
4/3-way hand lever valve
recirculating mid-position 1 1 1 1 1 1 1 1
Hydraulic power pack 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Hose line, 600 mm 3 5 5 6 5 4 7 5 9 4 12 5 12 10 11 8 5 12 4
Hose line, 1000 mm 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2
Stop-watch 1 1 1 1 1 1 1 1
Pressure sensor (2) 2 2
Flow-rate sensor 1 1 1 1 1
Universal display 1 1 1 1 1
Power supply unit 1 1 1 1 1 1
*) If a sufficient number of directly-controlled pressure relief valves is not available,

the pilot-operated pressure relief valve can also be used.

25
Electrical equipment for exercise 20
Description Order No. Qty.
4/3-way solenoid valve, relieving mid-position 167084 1

Signal input unit, electrical 162242 1
Relay, 3-fold 162241 1
Cable set 167091 1
The exercises appear in Section A of the workbook, with solutions to Methodological

these in Section C. The methodological structure is the same for all ex- structure of exercises
ercises.
The exercises in Section A are structured as follows:
Subject
Title
Training aim(s)
Problem definition
Exercise
Positional sketch
A worksheet then follows for use in carrying out the exercise.
The solutions in Section C contain the following:

Hydraulic circuit diagram
Practical assembly
Component list
Solution description
Evaluation
Conclusions

26

A-1
Section A – Course
Exercise 1: Automatic lathe
Pump characteristic A-3
Exercise 2: Package lifting device
Pressure relief valve characteristic A-7
Exercise 3: Drawing press
Hydraulic resistances A-11
Exercise 4: Calender feeding device
Single-acting cylinder (basic circuit) A-15
Exercise 5: Hardening furnace
Single-acting cylinder
(measurement and calculation) A-19
Exercise 6: Furnace door control
Double-acting cylinder A-23
Exercise 7: Conveyor tensioning device
4/3-way valve with bypass to pump A-29
Exercise 8: Cold-store door
Accumulator A-33
Exercise 9: Rotary machining station
Flow control valve and counter-holding A-37
Exercise 10: Painting booth
Flow control valve characteristic A-41
Exercise 11: Embossing machine
One-way flow control valve and counter-holding A-45
Exercise 12: Surface grinding machine
Differential circuit A-49
Exercise 13: Drilling machine
Pressure regulator A-55
Exercise 14: Bulkhead door
Hydraulic clamping of a cylinder A-59

A-2
Exercise 15: Ferry loading ramp

Flow control valve in inlet and outlet lines A-63
Exercise 16: Skip handling
Varying load A-69
Exercise 17: Bonding press
Comparison of pressure regulator and –
pressure relief valve A-73
Pressure sequence circuit,
displacement-step diagram A-77
Calculation of pressure and time A-81
Exercise 20: Tipping container
Electrohydraulics A-85

A-3
Exercise 1
Hydraulics Subject
Automatic lathe Title
To teach the student how to draw the characteristic curve for a pump Training aim
Drawing the hydraulic circuit diagram Problem definition

Practical assembly of the circuit
Determining the various measured values and entering them into the
table
Drawing the characteristic curve for the pump
Drawing conclusions

A-4
Exercise 2
Exercise The main spindle on an automatic lathe is driven by a hydraulic motor,

while a hydraulic cylinder is used to execute a feed movement of the
workpiece slide. It has been established that the specified speed is no
longer reached during the processing cycle. The pump characteristic
curve is therefore to be evaluated.
Positional sketch

A-5
Exercise 1
EXERCISE SHEET
System pressure p 15 20 25 30 35 40 45 50 bar Evaluation

Flow rate q l/min
Pump characteristic
How does the flow rate change as the pressure increases? Conclusion

A-6
Exercise 2

A-7
Exercise 2
Hydraulics Subject
Package lifting device Title
To teach the student how to draw the characteristic for a Training aim
pressure relief valve

Setting a maximum pressure of 50bar
Establishing the opening pressure of the pressure relief valve
Determining the various measured values and entering them
into the table
Drawing the pressure/flow rate characteristic
Drawing conclusions

A-8
Exercise 2
Exercise Owing to a change in the production process, a package lifting device is

now required to lift heavier packages than those for which it was origi-
nally designed. It has been observed that the stroke speed is now lower.
Using the pressure/flow rate characteristic for the pressure relief valve,
determine the pressure at which flow diversion of the pump output be-
gins.
Positional sketch
1A

A-9
Exercise 2
EXERCISE SHEET
Working pressure p 35 40 42.5 45 47.5 50 bar Evaluation

Flow rate q l/min
Characteristic for
pressure relief valve
How great is the difference between the opening pressure and maxi- Conclusion
mum pressure?

A-10
Exercise 2

A-11
Exercise 3
Hydraulics Subject
Drawing press Title
To teach the student how to measure flow resistances Training aim

Setting a constant flow rate
Measuring the flow resistances
Drawing conclusions

A-12
Exercise 3
Exercise A drawing press is used to shape metal workpieces. Following modifica-

tion of the hydraulic system, the workpieces are no longer dimensionally
accurate. The reason for this may be that the required press pressure is
not being reached. Use a special test set-up to measure the hydraulic
resistance of the components used.
Positional sketch

A-13
Exercise 3
EXERCISE SHEET
p0Z3 = Pressure upstream of component Evaluation

p0Z4 = Pressure downstream of component
Component Flow rate Pressure Pressure Pressure Values table

q p0Z3 p0Z4 difference
l/min bar bae ∆p
bar
Pressure relief 2
valve,
fully open 1
2
Throttle valve,
fully open 1
2
4/2-way valve,
P –> A 1
2
4/3-way valve,
P –> A 1
How does the pressure difference change when the flow rate is dou- Conclusion
bled?

A-14
Exercise 3

A-15
Exercise 4
Hydraulics Subject
Calender feeding device Title
To familiarise the student with the applications of a non-return valve Training aim
To show the activation of a single-acting cylinder using a 2/2-way
valve

Evaluation of this circuit

A-16
Exercise 4
Exercise Rolls of paper are lifted into a calender by a lifting device. The lifting
device is driven by a plunger cylinder (single-acting cylinder). When the
hydraulic power pack is switched on, the pump output flows directly to
the cylinder. A 2/2-way valve, which is closed in its normal position, is
fitted in a branch line leading to the tank. A non-return valve is used to
ensure that the pump is protected against the oil back-pressure. A pres-
sure relief valve is fitted upstream of the non-return valve to safeguard
the pump against excessive pressures.
Positional sketch

A-17
Exercise 4
EXERCISE SHEET
Circuit diagram, hydraulic

A-18
Exercise 4
Components list Item no. Qty. Description
Conclusion What is the disadvantage of this circuit?

A-19
Exercise 5
Hydraulics Subject
Hardening furnace Title
To familiarise the student with the applications of a 3/2-way valve Training aim
To show how to determine times, pressures and forces during the
advance and return strokes of a single-acting cylinder

Determining the necessary components
Measuring the travel pressure and travel time for the advance and
return strokes
Calculating the required advance-stroke pressure
Calculating the advance-stroke speed and time

A-20
Exercise 5
Exercise The cover of a hardening furnace is to be raised by a single-acting cyl-

inder. The cylinder is activated by a 3/2-way valve. A 9 kg weight is at-
tached to the cylinder to represent the load. Measure and calculate the
following values:
Travel pressure, load pressure, resistances and back pressure
Advance-stroke time and speed
Positional sketch

A-21
Exercise 5
EXERCISE SHEET
Direction Travel pressure Travel time Evaluation
Advance stroke
Return stroke
Characteristic data required for calculation:

Applied load: FG = 90 N
2
Piston area: APN = 2 cm
Stroke length: s = 200 mm
Pump output: q = 2 l/min
FG
Load pressure: pL =
A PN
pL =
Hydraulic resistance = Travel pressure - load pressure
p res =
How great is the back pressure in relation to the hydraulic resistance? Conclusion

A-22
Exercise 5
q
Advance-stroke speed: v adv =
A PN
v adv =
s
Advance-stroke time: t adv =
v adv
t adv =
Conclusion Do the calculated and measured advance-stroke times agree?

A-23
Exercise 6
Hydraulics Subject
Furnace door control Title
To show how to determine times, pressures and forces during the
advance and return strokes of a double-acting cylinder

Practical assembly of circuit
Measuring the travel and back pressures and transfer time for the
advance and return strokes
Calculation of advance and return-stroke speeds
Comparison of calculated and measured values

A-24
Exercise 6
Exercise A furnace door is opened and closed by a double-acting cylinder. The

cylinder is activated by a 4/2-way valve with spring return. This ensures
that the door opens only as long as the valve is actuated. When the
valve actuating lever is released, the door closes again.
Positional sketch

A-25
Exercise 6
EXERCISE SHEET

A-26
Exercise 6
Evaluation Advance stroke Travel pressure Back pressure Travel time

p1S1 p1S2 tadv
Return stroke Back pressure Travel pressure Travel time

p1S1 p1S2 tret

2
Piston area: APN = 2.0 cm
2
Piston annular area: APR = 1.2 cm
A PN
Area ratio: α=
A PR
α=
q
Advance-stroke speed.: v adv =
A PN
Vadv =
s
Advance-stroke time: t adv =
v adv
t adv =
q
Return-stroke speed: v ret =
A PR
Vret =

A-27
Exercise 6
s
Return-stroke time: t ret =
v ret
t ret =
Ratio of travel speeds:
Vadv
=
Vret
Ratio of travel times:
t adv
=
t ret
Compare the advance- and return-stroke speeds and times with the Conclusion
area ratio. What is the relationship between these?

A-28
Exercise 6

A-29
Exercise 7
Hydraulics Subject
Conveyor tensioning device Title
To show how to use a piloted non-return valve

Measuring travel and back pressure and the system pressure in all
valve positions
Calculating the power balance for circuits with various 4/3-way valves
with different mid-positions

A-30
Exercise 7
Exercise Parts are fed through a drying oven on a steel chain conveyor belt. It
must be possible to correct the tracking of the belt by means of a ten-
sioning device to ensure that the belt does not run off its rollers. This
device consists of a steel roller fixed at one end and movable at the
other by means of a double-acting cylinder. Hydraulic power must be
available continuously. The hydraulic system must switch to the recircu-
lating (pump bypass) condition when the directional control valve is not
actuated. The clamping station causes a continuous counter force to act
on the cylinder. A piloted non-return valve is used to prevent creepage
of the piston rod of the positioning cylinder as a result of oil leakage
losses in the directional control valve.
For the purposes of comparison, calculate the required drive power for
circuits firstly with a 4/3-way valve, recirculating in mid-position and sec-
ondly with a 4/3-way valve, closed in mid-position.
Positional sketch

A-31
Exercise 7
EXERCISE SHEET

A-32
Exercise 7
Evaluation Direction Valve position System Travel and back pressure

pressure
p0Z2 p1S1 p1S2
Advance stroke
Return stroke
Mid-position
p⋅q
Calculation of drive power:: PDR =
η
PDR = Required drive power
p = System pressure supplied by pump: Maximum 50 bar
q = Flow rate of pump: Constant 2 l/min
η = Pump efficiency: Approx. 0.7
Drive power with closed mid-position:
PDR =
Drive power with recirculating mid-position:
PDR =
Conclusion What is the advantage of a recirculating (bypass) circuit?

A-33
Exercise 8
Hydraulics Subject
Cold-store door Title
To show the use of a hydraulic accumulator as a power source Training aim

To show how to use the accumulator to power advance and return
strokes of the cylinder after the pump is switched off

Determining the number of working cycles possible after the pump is
switched off
Drawing conclusions
Explaining the design and mode of operation of a diaphragm accumu-
lator
Naming possible applications of an accumulator

A-34
Exercise 8
Exercise A heavy cold-store door is opened and closed by a hydraulic cylinder. A

hydraulic accumulator is to be installed to allow the door to be closed in
the case of an electrical power failure. This will permit the cold-store
door to be opened and closed a number of times. A 4/2-way valve is to
be used to activate the cylinder. This valve should be connected up in
such a way that the piston rod is advanced with the valve in its normal
position.
No provision will be made here for the safety cut-out which is essential
to prevent persons from becoming trapped in the door. This cut-out
function is normally provided by an electrical control device for the hy-
draulic system.
Be sure to follow the operating instructions for the accumulator. After

switching off the control system, do not dismantle the hydraulic compo-
nents until you have relieved the pressure in the accumulator and iso-
lated this from the control system by means of the built-in shut-off valve.
It is essential to relieve the accumulator pressure via a flow control
valve!
Positional sketch

A-35
Exercise 8
EXERCISE SHEET

A-36
Exercise 8
Evaluation System pressure Opening Closing
20 bar
50 bar
Conclusion What is the effect of fitting an accumulator to this circuit?
Explain the design and function of a diaphragm accumulator.
Name examples of applications of accumulators.

A-37
Exercise 9
Hydraulics Subject
Rotary machining station Title
To familiarise the student with the use of a 2-way flow control valve Training aim
To show how to assemble a counter-holding circuit
Understanding of a hydraulic circuit diagram Problem definition

Commissioning a circuit with a flow control valve and counter-holding
Adjustment and measurement of inlet and outlet pressures and cylin-
der travel time
Comparison of cylinder advance-stroke times for various inlet and
outlet pressures

A-38
Exercise 9
Exercise Several stations on a rotary machining station are driven by a hydraulic

power pack.
As individual stations are switched on and off, they produce pressure
fluctuations throughout the hydraulic circuit. This effect will be studied
on a drilling station. The fluctuations in pressure and the tractive forces
created during drilling must not affect the feed of the drilling station. A
flow control valve is to be used to ensure a smooth adjustable feed rate,
while a pressure relief valve is to be used as a counter-holding valve to
compensate for the tractive forces.
Positional sketch

A-39
Exercise 9
EXERCISE SHEET

A-40
Exercise 9
Evaluation Measure the following:

p1Z1 = Pressure upstream of flow control valve
p1Z3 = Pressure downstream of flow control valve
p1Z4 = Pressure at counter-holding valve
t→ = Advance-stroke time of cylinder
Fluctuating p1Z1 p1Z3 p1Z4 t→

inlet pressure
50 bar 10 bar
40 bar 10 bar
30 bar 10 bar
20 bar 10 bar
10 bar 10 bar

outlet pressure
50 bar 10 bar
50 bar 20 bar
50 bar 30 bar
50 bar 40 bar
50 bar 50 bar
Conclusion How does the travel change as the pressures at the inlet and outlet
vary?

A-41
Exercise 10
Hydraulics Subject
Painting booth Title
To show how to plot a characteristic for a 2-way flow control valve Training aim
To show how to make a comparison between a 2-way flow control
valve and a throttle-type flow control valve

Measurement of pressure and flow rate
Plotting the characteristic of the 2-way flow control valve
Comparison with a throttle valve

A-42
Exercise 10
Exercise An endless chain conveyor feeds workpieces through a painting booth.

The chain is driven by a hydraulic motor via a right-angle gear unit. Due
to changes in the production process, the weight of the workpieces
passing through the painting booth has changed. The speed of the con-
veyor should, however, remain the same as before. It must be deter-
mined whether this can be achieved by fitting a flow control valve, and if
so which type is suitable.
Positional sketch

A-43
Exercise 10
EXERCISE SHEET
Measure the following: Evaluation

p1Z1 = Pressure upstream of valve
p1Z2 = Pressure downstream of valve
qTWFCV = Flow rate through 2-way flow control valve
qTV = Flow rate through throttle valve
p1Z1 p1Z2 qSRV qDV Fluctuating

load pressure
50 bar 10 bar 2 l/min 2 l/min
50 bar 20 bar
50 bar 30 bar
50 bar 40 bar
50 bar 50 bar

inlet pressure
40 bar 10 bar
30 bar 10 bar
20 bar 10 bar
10 bar 10 bar

A-44
Exercise 10
Flow control valve

characteristic
Conclusion Which valve is suitable for this application and why?

A-45
Exercise 11
Hydraulics Subject
Embossing machine Title
To familiarise the student with the use of a one-way flow control valve Training aim
To show how to explain the difference between a flow control valve
and throttle valve on the basis of a concrete application

Commissioning a circuit with a one-way flow control valve and
counter-holding
Adjustment and measurement of inlet and outlet pressures and cylin-
der advance-stroke time
Comparison of advance-stroke times with those in exercise 9

A-46
Exercise 11
Exercise A special machine is used to emboss graphic symbols on metal foil. The
foil is fed through the embossing machine with an adjustable cycle time.
The downward motion of the stamp must be capable of being varied in
accordance with the feed speed. The return motion must always be
executed as a rapid traverse.
A one-way flow control valve is used to control the speed of the stamp,
while a pressure relief valve is used to prevent the weight of the stamp
from pulling the piston rod out of the cylinder. A 4/2-way valve is used to
switch between upwards and downwards motion.
Positional sketch

A-47
Exercise 11
EXERCISE SHEET

A-48
Exercise 11

p1Z1 = Pressure upstream of one-way flow control valve
p1Z3 = Pressure downstream of one-way flow control valve
t→ = Cylinder advance-stroke time

inlet pressure
50 bar 10 bar
40 bar 10 bar
30 bar 10 bar
20 bar 10 bar
10 bar 10 bar

outlet pressure
50 bar 10 bar
50 bar 20 bar
50 bar 30 bar
50 bar 40 bar
50 bar 50 bar
Conclusion How does the travel time change as the pressures at the inlet and outlet
vary?
What is the difference between this circuit and the one with the 2-way
flow control valve (see exercise 9) and what is the reason for this?

A-49
Exercise 12
Hydraulics Subject
Surface grinding machine Title
To familiarise the student with the design and mode of operation of a Training aim
differential circuit
To show how to explain the influence of pressures, forces, speeds
and travel times
Understanding a hydraulic circuit diagram Problem definition

Measuring advance and return stroke times and travel and back
pressures
Calculation of ratios for area and force
Calculation of the flow rate through the flow control valve
Comparison of this circuit with the one in exercise 6

A-50
Exercise 12
Exercise The grinding table of a surface grinding machine is driven by a hydraulic

cylinder. Since the speed is required to be the same in both directions,
the hydraulic control circuit must be designed to provide compensation
for the difference in volume of the two cylinder chambers. A differential
circuit is suggested with a 3/2-way valve and a flow control valve for
speed adjustment.
Positional sketch

A-51
Exercise 12
EXERCISE SHEET

A-52
Exercise 12

p1Z1 = Pressure on piston side of cylinder
p1Z2 = Pressure on annular side of cylinder
p0Z2 = System pressure = 50 bar
t→ = Cylinder advance-stroke time approx. 4 s
Values table Direction p1Z1 p1Z2 t
Advance stroke
Return stroke
Cylinder dimensions:
2
2
Cylinder stroke: s = 0.2 m
A PN
Area ratio: α= =
A PR
t adv
Time ratio: =
t ret
F1 A PN ⋅ p1Z1
Force ratio: = =
F2 A PR ⋅ p1Z 2
Flow rate during advance stroke:
s
Piston side: qPN = A PN ⋅ =
t adv
s
Piston annular side: qPR = A PR ⋅ =
t adv

A-53
Exercise 12
EXERCISE SHEET
Flow control valve component:
qFCV = qPN − qPR =
Flow rate during return stroke:
s
Piston annular side: qPR = A PR ⋅ =
t ret
When the 3/2-way valve is activated, the same pressure is present at Conclusion
both cylinder ports. Why does the piston advance?
During the advance stroke, the pressures in the two cylinder chambers
are different. Why does the piston advance despite the fact that the
travel pressure is lower than the back pressure?
What force can the cylinder exert during its advance stroke?

A-54
Exercise 12
What is the difference between this differential circuit and a simple cyl-
inder control circuit (one connection to each of P and T as, for example,
in exercise 6)?
1. What are the factors governing the advance-stroke speed vadv?
2. What is the value of the return-stroke speed vret in comparison with
the advance-stroke speed vadv?
3. What are the factors governing the advance-stroke time tadv?
4. What is the value of the return-stroke time tret in comparison with the
advance-stroke time tadv?
Vergleich System Simple cylinder control circuit Differential circuit
1. Advance-stroke speed
vadv
2. Return-stroke speed vret
3. Advance-stroke time
tadv
4. Return-stroke time
tret
Conclusion What area ratio results in identical advance and return stroke speeds
(using a differential circuit)?

A-55
Exercise 13
Hydraulics Subject
Drilling machine Title
To teach the student how to design a control circuit with reduced out- Training aim
put pressure
To show how to explain the mode of operation of a 3-way pressure
regulator

Measuring the travel and back pressures
Setting a counter pressure
Assessment of the effect of using a pressure regulator

A-56
Exercise 13
Exercise A drilling machine is used for work on various hollow workpieces. The
workpieces are hydraulically clamped in a vice. It must be possible to
reduce the clamping pressure to suit the design of the workpiece. It
must also be possible to vary the closing speed by means of a one-way
flow control valve.
Positional sketch
1A

A-57
Exercise 13
EXERCISE SHEET
Measure the following: Evaluation

p1Z1 = Pressure upstream of flow control valve
p1Z2 = Pressure upstream of cylinder
p1Z3 = Pressure downstream of cylinder
Study the following cases:

1. Piston advance stroke
2. Piston advanced to end position with setting p1Z2 = 15 bar.
3. Piston advance stroke with counter pressure setting, p1Z3 = 20 bar.
4. Piston advanced to end position
5. Piston advance stroke with shut-off valve closed
6. Piston advanced to end position with shut-off valve closed
Cases of examination p1Z1 p1Z2 p1Z3 Advance stroke
1. Advance stroke
2. End position
3. Advance stroke with counter pressure
4. End position
5. Advance stroke with pressure regulator
6. End position
Cases of examination p1Z1 p1Z2 p1Z3 Return stroke
1. Return stroke
2. End position
3. Return stroke with counter pressure
4. End position
5. Return stroke with pressure regulator
6. End position

A-58
Exercise 13
Conclusion When is it appropriate to use a pressure regulator?
What possible disadvantage may result from the use of a pressure

regulator?

A-59
Exercise 14
Hydraulics Subject
Bulkhead door Title
To familiarise the student with a circuit for the hydraulic clamping of a Training aim
bulkhead door
To demonstrate a comparison of circuits with and without counter-
holding

Measuring the cylinder advance-stroke time with and without a load
and with and without counter-holding
Comparison and assessment of results

A-60
Exercise 14
Exercise A double-acting cylinder is used to open and close a bulkhead door.

Closing must be carried out smoothly and at a constant adjustable
speed. The speed is adjusted by means of a one-way flow control valve.
A pressure relief valve must be fitted to provide counter-holding and
prevent the heavy door from pulling the piston rod out of the cylinder
during the closing operation.
Positional sketch

A-61
Exercise 14
EXERCISE SHEET

A-62
Exercise 14

p1Z1 = Cylinder travel pressure
p1Z2 = Cylinder back pressure
p0Z2 = System pressure
The applied load and counter-holding should now be varied. Initial set-
tings should be such as to achieve an advance-stroke time of 5 s with a
system pressure of 50 bar but without an applied load or counterholding.
10 bar back pressure should subsequently be set.
When dismantling the circuit, ensure that no pressurised fluid is trapped

(p1Z2 = 0 bar).
Values table Load and counter-holding p0Z2 p1Z1 p1Z2 t→
Without load or counter-holding 50 bar 5s

With load without counter-holding
With load and counter-holding 10 bar

Without load with counter-holding 10 bar
Conclusion How does the travel time vary as the load changes?
Which circuit is more suitable?

A-63
Exercise 15
Hydraulics Subject
Ferry loading ramp Title
To familiarise the student with a speed control circuit with a tractive Training aim
load
To compare circuits with flow control valves in the inlet line and outlet
line respectively

Measuring the cylinder advance time and travel and back pressures
with flow control valves in the inlet line and outlet line respectively
Comparison and assessment of results

A-64
Exercise 15
Exercise The loading ramp of a car ferry must be capable of being set to different
heights. The ramp is raised and lowered by a hydraulic cylinder. This
motion must be carried out smoothly and at a constant speed. A flow
control valve is to be used to adjust the speed. This must be installed in
such a way as to prevent excessive pressures from developing within
the system.
Positional sketch

A-65
Exercise 15
EXERCISE SHEET

A-66
Exercise 15

Vary the following:

Applied load
Counter-holding
Flow control in inlet and outlet lines
Settings:
First, without an applied load or counter-holding and with a flow con-
trol valve in the inlet line, make settings to obtain an advance-stroke
time of t –> = 5 s with a system pressure of p0Z2 = 50 bar.
Then set a counter pressure of p1Z2 = 10 bar.
Then use a flow control valve in the outlet line to provide counter-
holding.
When dismantling the circuit, ensure that no pressurised fluid is trapped

(p1Z2 = 0 bar).

A-67
Exercise 15
EXERCISE SHEET
Load and counter-holding p0Z2 p1Z1 p1Z2 t→ Flow control valve

in inlet line
Without load or counter-holding 50 bar 5s
With load without counter-holding
With load and counter-holding 10 bar

Without load with counter-holding 10 bar
Load p0Z2 p1Z1 p1Z2 t→ Flow control valve

in outlet line
Without load 50 bar 5s
With load
How does the travel time change as the load is varied? Conclusion
Which circuit is more suitable?

A-68
Exercise 15

A-69
Exercise 16
Hydraulics Subject
Skip handling Title
To develop a hydraulic circuit for a double-acting cylinder subject to a Training aim

varying load
Drawing the circuit diagram Problem definition

Commissioning of control circuit
Description of mode of operation of control circuit

A-70
Exercise 16
Exercise The loading and unloading of skips from a skip transporter is carried out
using two double-acting cylinders. Each cylinder is subject to varying
loads – tractive load during unloading and compressive load during
loading. The skip should be raised and lowered at a slow constant
speed. Each cylinder must therefore be hydraulically clamped on both
sides.
Positional sketch

A-71
Exercise 16
EXERCISE SHEET

A-72
Exercise 16
Conclusion How is hydraulic clamping produced on both sides?

A-73
Exercise 17
Hydraulics Subject
Bonding press Title
To teach the student how to specify the pressure for a double-acting Training aim
cylinder

To show how to choose either a pressure relief valve or a pressure
regulator

Measurement and comparison of system pressure, travel pressure
and final pressure
Assessment of the suitability of a pressure relief valve and pressure
regulator

A-74
Exercise 17
Exercise A bonding press is used to stick pictures or lettering onto wood or plastic
panels. The working pressure must be adjustable to suit the base mate-
rial and adhesive used and must be capable of being maintained for a
long time while the directional control valve is activated.
Develop and compare two circuits. The first should use a 3-way pres-
sure regulator to adjust the press pressure, while the second should
incorporate a pressure relief valve connected into the bypass line for this
purpose. A 4/3-way valve should be used for activation in both cases.
Positional sketch

A-75
Exercise 17
EXERCISE SHEET

A-76
Exercise 17
Evaluation Carry out the following settings:

p1Z2 = Pressure upstream of cylinder = 30 bar
Conclusion With which circuit does the system pressure vary as the cylinder ad-
vances?
When is it advantageous to use the pressure relief valve?

A-77
Exercise 18
Hydraulics Subject
Assembly device Title
To familiarise the student with a pressure sequence circuit Training aim

To teach the student how to draw a displacement-step diagram
Development of hydraulic circuit diagram Problem definition

Drawing the displacement-step diagram
Systematic commissioning with setting of pressure and flow rate

A-78
Exercise 18
Exercise An assembly device is used to press workpieces together for drilling.

Cylinder 1A1 presses a workpiece into the housing. This operation
should be carried out slowly at a constant speed. When the pressure in
cylinder 1A1 has reached 20 bar (workpiece pressed into place), a hole
is drilled through the workpiece and housing. The drill is driven by a hy-
draulic motor. After the drilling operation, the drill is switched off and
retracted (1A2). Cylinder 1A1 is retracted only when the drill has with-
drawn from the housing.
Positional sketch
1A1
1A2

A-79
Exercise 18
EXERCISE SHEET

A-80
Exercise 18
Displacement-step diagram Time

Components
Step
Designa
Description Signal
tion
Conclusion What are the points to note when commissioning the control circuit?
1.
2.
3.
4.
5.
6.

A-81
Exercise 19
Hydraulics Subject
Calculations for an assembly device Title
To enable the student to calculate the forces associated witha dou- Training aim
ble-acting cylinder
To enable the student to calculate the advance-stroke time of a cylin-
der piston
Writing a problem description Problem definition

Calculating the press-fitting force
Calculating the press-fitting time

A-82
Exercise 19
Exercise An assembly device is used to press workpieces together for drilling.

The operating sequence is described in exercise 18. Our objective here
is to check the pressing operation of cylinder 1A1 mathematically. De-
termine the press-fitting force using the given data. Note that, while the
press-fitting pressure is available as specified, the resistances of the
lines and directional control valve cause an opposing pressure to act on
the annular piston side, thus reducing the actual force available.The flow
rate is kept constant by a flow control valve. This together with the cylin-
der stroke is used to calculate the travel time for the press-fitting opera-
tion.
Positional sketch
1A1

A-83
Exercise 19
EXERCISE SHEET
Characteristic data of control system: Evaluation
Cylinder:
Piston diameter D = 50 mm
Piston rod diamete d = 25 mm
Stroke s = 250 mm
Hydraulic system:
Flow rate q = 5 l/min
Press-fitting pressure p1 = 50 bar
Counter pressure p2 = 6 bar
Schematic diagram

A-84
Exercise 19
Piston force:
F1 = A PN ⋅ p1 =
Counter force:
F2 = A PR ⋅ p 2 =
Press-fitting force:
F = F1 − F2 =
Press-fitting time:
V
t= =
q

A-85
Exercise 20
Hydraulics Subject
Tipping container Title
To familiarise the student with an electrohydraulic circuit Training aim
Development of hydraulic and electrical circuit diagrams Problem definition

Assembly of control system

A-86
Exercise 20
Exercise A conveyor belt transports metal swarf into a tipping container. When
the container is full, it is emptied into a truck. A double-acting cylinder is
used for this purpose, activated by a solenoid-actuated 4/3-way valve.
The piston rod of the cylinder is advanced while the container is in posi-
tion to receive swarf. To enable the hydraulic power pack to be switched
off during this time, the piston rod of the cylinder must be protected by
hydraulic means against undesired retraction (caused by leakage in the
valve). The electrical activation of the valve must be manually controlled,
i.e. the cylinder must move only when the “Up” or “Down” pushbuttons
are pressed.
Positional sketch

A-87
Exercise 20
EXERCISE SHEET

A-88
Exercise 20
Circuit diagram,electrical
S1 = “Up” pushbutton
S2 = “Down” pushbutton
Conclusion What measure ensures that the cylinder maintains its position and does
not move even if the “Up” and “Down” pushbuttons are accidentally
pressed simultaneously?

B-1
Fundamentals
Section B – Fundamentals
The theoretical fundamentals for the “Hydraulics” training package are
summarised in the textbook:
Hydraulics
Basic Level TP501

B-2
Fundamentals

C-1
Section C – Solutions
Solution 1: Automatic lathe C-3
Solution 2: Package lifting device C-7
Solution 3: Drawing press C-11
Solution 4: Calender feeding device C-15
Solution 5: Hardening furnace C-19
Solution 6: Furnace door control C-23
Solution 7: Conveyor tensioning device C-27
Solution 8: Cold-store door C-33
Solution 9: Rotary machining station C-37
Solution 10: Painting booth C-41
Solution 11: Embossing machine C-45
Solution 12: Surface grinding machine C-49
Solution 13: Drilling machine C-59
Solution 14: Bulkhead door C-65
Solution 15: Ferry loading ramp C-69
Solution 16: Skip handling C-73
Solution 17: Bonding press C-77
Solution 18: Assembly device C-79
Solution 19: Calculation for an assembly device C-83
Solution 20: Tipping container C-85

C-2

C-3
Solution 1
Automatic lathe
Practical assembly,
hydraulic

C-4
Solution 1
0Z1 1 Hydraulic power pack

0Z2 1 Pressure gauge
1V 1 Shut-off valve
1S 1 Flow sensor
3 Hose line
Solution description Once the hydraulic circuit has been assembled, valve 1V should be fully
opened. Now close this valve slowly to set the first p value as shown on
the pressure gauge 0Z2. The maximum attainable pressure is 60 bar,
governed by a pressure relief valve built into the pump which is set to
this value.
Evaluation System pressure p 15 20 25 30 35 40 45 50 bar

Flow rate q 2.33 2.31 2.29 2.28 2.26 2.24 2.22 2.20 l/min
Pump characteristic

C-5
Solution 1
As the pressure rises, the pump delivery falls slightly. In theory, the Conclusions
characteristic curve for the pump should be a straight line.The decrease
in pump delivery is due to internal leakage losses, which become
greater as the pressure increases The ratio of the measured pump de-
livery and theoretical pump delivery is the effective volumetric efficiency
of the pump.
For technical reasons, the actual value recorded in this exercise is the
power consumption of the electric motor or the premature opening of the
pressure relief valve. The pump is dimensioned for a maximum pressure
of 250 bar (see data sheet). An electric motor with an appropriately high
rating would be required to achieve this. This would not, however, be
meaningful, since the exercises are carried out with a maximum pres-
sure of 60 bar.

C-6
Solution 1

C-7
Solution 2
Package lifting device

C-8
Solution 2
Practical assembly,
hydraulic
System pressure
p = 50 bar (5 MPa)
(Shut-off valve 1V1
closed)
Measured
value
q in
l/min
Pump safety valve

pmax = 60 bar (6 MPa)

1V1 1 Shut-off valve
1V2 1 Pressure relief valve
1S 1 Flow sensor
5 Hose line
2 Branch tee

C-9
Solution 2
Once the hydraulic circuit has been assembled and checked, valve 1V1 Solution description
should be closed and the pressure relief valve 1V2 fully opened. Switch
on the hydraulic power pack and close the pressure relief valve until the
pressure gauge 0Z2 indicates 50 bar. Now fully open shut-off valve 1V1
and close it again in steps to set the pressures specified in the table;
evaluate the associated flow rates. At the same time, observe the pres-
sure at which the valve begins to open.
If, at 50 bar pressure, a flow rate of 2.3 l/min is not measured at the Remark
pressure relief valve, this indicates that the pressure relief valve fitted
directly to the pump is already starting to open.
Working pressure p 35 40 42.5 45 47.5 50 bar Evaluation
Flow rate q 0 0 0 0.2 1.17 2.15 l/min
Pressure relief
valve characteristic
Maximum pressure
Opening pressure

C-10
Solution 2
Conclusions Every pressure relief valve has a certain opening pressure at which
point diversion of the flow through the valve begins. The difference be-
tween opening pressure and maximum pressure is 5 bar in this case.
When the preset maximum pressure is reached, the entire pump deliv-
ery is discharged via the pressure relief valve.
A piloted pressure relief valve can also be used to record the character-
istic. Due to the low flow rate, the same shape of characteristic curve
will be obtained.

C-11
Solution 3
Drawing press

C-12
Solution 3
Practical assembly,
hydraulic
System pressure
p = 50 bar (5 MPa)

C-13
Solution 3
Item no. Qty. Description Components list

0Z2, 0Z3, 0Z4 3 Pressure gauge
0V2 1 Flow control valve
1V3 1 Throttle valve
1V2 1 4/2-way valve
1V1 1 4/3-way valve
1S 1 Flow sensor
7 Hose line
3 Branch tee
Once the hydraulic circuit has been assembled and checked, the shut- Solution description
off valve 0V3 should be closed and the pressure relief valve 0V1 fully
opened. Switch on the hydraulic power pack and close the pressure
relief valve until the pressure gauge 0V1 indicates 50 bar. Now carry out
the series of measurements specified in the table. Adjust the flow rate
by means of the flow control valve 0V2 and measure it with the flow
sensor 1S.
Pressure sensors are recommended for the measurement of pressures

at items 0Z3 and 0Z4.

C-14
Solution 3
Evaluation p0Z3 = Pressure upstream of component

p0Z4 = Pressure downstream of component
Values table Component Flow rate Pressure Pressure Pressure difference

q p0Z3 p0Z4 ∆p
l/min bar bar bar
Pressure relief 2 4.6 2.5 2.1

valve,
fully open 1 1.9 1.0 0.9
2 4.3 2.5 1.8
Throttle valve,
fully open 1 1.9 1.2 0.7
2 4.0 2.5 1.5
4/2-way valve,
P –> A 1 1.9 1.2 0.7
2 4.3 2.5 1.8
4/3-way valve,
P –> A 1 1.8 1.1 0.7
Conclusions When the flow rate doubles, the pressure difference increases by even
more than this. The hydraulic resistance increases. This pressure loss
means a loss of power.

C-15
Solution 4
Calender feeding device

C-16
Solution 4
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety valve


C-17
Solution 4

0V1 1 Non-return valve (5 bar)
1V 1 Shut-off valve
1A 1 Cylinder, double-acting
1Z 1 Loading weight
8 Hose line
4 Branch tee
For this exercise, the cylinder is bolted onto the base plate on the left of Solution description
the profile plate and loaded with the weight. When the cylinder is con-
nected up, it is essential that the upper connection is connected to the
tank. Once the circuit has been assembled, the PRV 0V2 should first be
fully opened. The hydraulic power pack should then be switched on and
the PRV 0V2 slowly closed. The piston rod will then travel to its upper
end position. Continue to close the PRV until the pressure gauge 0Z2
indicates 50bar. Now switch off the hydraulic power pack. It can be
demonstrated by briefly opening the shut-off valve that the non-return
valve prevents the weight from lowering further and that return flow of
hydraulic fluid during the return stroke can take place only via the 2/2-
way valve 1V.
The piston rod can retract only when the pump is switched off. This is Conclusions
arranged intentionally in systems like the one shown here. This ensures
that the hydraulic power pack is switched off during lengthy standstill
periods.

C-18
Solution 4

C-19
Solution 5
Hardening furnace

C-20
Solution 5
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

C-21
Solution 5

0V1 1 Non-return valve
1V 1 4/2-way valve, manually operated
1Z2 1 Loading weight
7 Hose line
3 Branch tee
1 Stop-watch
For this exercise, the cylinder is bolted onto the base plate on the left of Solution description
the profile plate and loaded with the weight. When the cylinder is con-
nected up, it is essential that the upper connection is connected to the
tank. In place of a 3/2-way valve, a 4/2-way valve is now used, with one
connection blanked off. Once the circuit has been assembled, the PRV
0V2 should first be fully opened. The hydraulic power pack should then
be switched on and the PRV 0V2 slowly closed until the pressure gauge
0Z3 indicates 50 bar. The 4/2-way valve 1V can now be slowly reversed,
which will cause the piston rod of the cylinder to advance. The design of
the valve means that, as this is slowly reversed, the full cross-section of
the valve is not immediately opened. Initially, the pump delivery to the
cylinder will be throttled. As soon as the valve is returned to its initial
position, the piston rod of the cylinder will return to its lower end posi-
tion.
The values specified in the tables can now be measured.
Direction Travel pressure Travel time Evaluation
Advance stroke 8 bar 1.1 s
Return stroke 0 bar 1.4 s

C-22
Solution 5

Applied load:: FW = 90 N
2
Piston area: APN = 2 cm
Pump delivery: q= 2 l/min
FW 90 N 45 N
Load pressure: pL = = 2
= = 4.5 bar
A PN 2 cm cm 2
Hydraulic resistance = Travel pressure - load pressure
pres = 8 bar - 4.5 bar = 3.5 bar
Conclusions The back pressure is considerably lower than the hydraulic resistance. A
cylinder motion can take place only if this case applies. The value of the
back pressure depends on the hydraulic resistances. These are very low
when fluid is discharged into the tank.
l 2000 cm 3
2
q 60 s
Advance-stroke speed: v adv = = min2 =
A PN 2 cm 2 cm 2
cm m
v adv = 16.67 = 0.17
s s
s 0.2 m
Advance-stroke time: t adv = = = 12
. s
v adv m
0.17
s
Conclusions The measured advance-stroke time, 1.1 s., is slightly less than the cal-
culated time. The reason for this may be that the delivery of a new pump
is somewhat greater than 2 l/min.

C-23
Solution 6
Furnace door control

C-24
Solution 6
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

1S1, 1S2 2 Pressure sensor
0V 1 Pressure relief valve
1A 1 Cylinder
6 Hose line
2 Branch tee
1 Stop-watch

C-25
Solution 6
Once the circuit has been assembled and checked, the hydraulic power Solution description
pack should be switched on and the system pressure set on the pres-
sure relief valve 0V to 50 bar. Pressure sensors should be used to
measure the travel and back pressures. Pressure gauges are sluggish
in operation and would give incorrect readings.
When the hand lever of the 4/2-way valve is actuated, the piston rod of
the cylinder will advance until the lever is released or the piston rod runs
against the stop. When the lever is released, the piston rod will imme-
diately return to its retracted end position. Before the pressures and
times are measured, the piston rod should be advanced and retracted
several times to expel any air which may have entered the piston-rod
chamber during the previous exercises.
Advance stroke Travel pressure Back pressure Travel time Evaluation

p1S1 p1S2 tadv
2.4 bar 2 bar 1.2 s
Return stroke Back pressure Travel pressure Travel time

p1S1 p1S2 tein
5.3 bar 11 bar 0.8 s

2
2
A PN 2 cm 2
Area ratio: α= = = 1667
.
A PR 12. cm 2
l 2000 cm 3
2
q 60 s
Advance-stroke speed: v adv = = min2 =
A PN 2 cm 2 cm 2
cm m
Vadv = 16.67 = 0.17
s s

C-26
Solution 6
s 2m
Advance-stroke time: t adv = = = 12
. s
v adv m
0.17
s
l 2000 cm 3
2
q min = 60 s
Return-stroke speed: v ret = = 2
A PR 12
. cm . cm 2
12
cm m
v ret = 27.78 = 0.28
s s
s 0.2 m
Return-stroke time: t ret = = = 0.7 s
v ret m
0.28
s
m
0.17
Vadv s = 0.6
Travel speed ratio: =
Vret m
0.28
s
t adv . s
12
Travel time ratio: = = 17
.
t ret 0.7 s
Conclusions The travel speed ratio is equal to the area ratio α of the cylinder. The
speed ratio is equal to the reciprocal of the area ratio.

C-27
Solution 7
Conveyor tensioning device

C-28
Solution 7
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety
valve
pmax = 60 bar
(6 MPa)

C-29
Solution 7

1S1, 1S2 2 Pressure sensor
1V1 1 4/3-way valve, manually operated, Recirculating mid-position
1V2 1 Pilot-operated non-return valve
1A 1 Cylinder
9 Hose line
3 Branch tee
1 Stop-watch
After the circuit has been assembled and tested, the shut-off valve 0V2 Solution description
should be closed and the pressure relief valve 0V1 opened. Switch on
the hydraulic power pack and close the PRV 0V1 until the pressure
gauge 0Z1 indicates 50 bar.
The shut-off valve 0V2 can now be opened. Observe when doing this
that the pressure gauge 0Z1 shows an immediate drop from the set
pressure of 50 bar to approx. 3 bar, since in its mid-position the 4/3-way
valve 1V1 discharges the flow of hydraulic fluid to the tank. The piston
rod can be brought into any desired position by actuating the 4/3-way
valve. When this valve is brought into its mid-position, the piston rod
immediately halts.
The non-return valve prevents the piston rod from being pushed back by
a counter force.

C-30
Solution 7
In conjunction with the pilot-operated non-return valve, a 4/3-way valve

with a mid-position “A and B connected to T” and “P closed” should be
used in order to depressurise the pilot line and supply line to the piloted
non-return valve. The non-return valve can close reliably only when de-
pressurised.
The 4/3-way valve with recirculating mid-position, included in the equip-
ment set, can also be used for these exercises. The internal leakage
losses resulting from the design of this valve will also cause the non-
return valve to close.
Evaluation Direction Valve position System Travel and back pressure

pressure
p0Z2 p1S1 p1S2
Advance stroke 8 bar 2.2 bar 1.6 bar
Return stroke 2.2 bar 9.4 bar 17.9 bar
Mid-position 3.1 bar 1.6 bar 1.7 bar
p⋅q
Calculation of drive power:: PDR =
η
PDR = Required drive power
p = System pressure supplied by pump: Maximum 50 bar
q = Flow rate of pump: Constant 2 l/min
η = Pump efficiency: Approx. 0.7

C-31
Solution 7
Drive power with closed mid-position:
l
50 bar ⋅ 2
min = 50 kp ⋅ 2 dm = 50 ⋅ 10 N ⋅ 2 ⋅ 1000 cm
3 3
PDR =
0.7 0.7 cm 2 ⋅ 60 s 0.7 cm ⋅ 60 s
50 ⋅ 2 Ncm 3 50 ⋅ 2 Nm
PDR = ⋅ 10000 = ⋅ 100 = 238 W
0.7 ⋅ 60 cm ⋅ s 0.7 ⋅ 60
2
s
Drive power with bypass to pump:
l
3.1 bar ⋅ 2
PDR = min = 3.1⋅ 2 ⋅ 100 Nm = 15 W
0.7 0.7 ⋅ 60 s
The 4/3-way valve with recirculating mid-position is mainly used in cases Conclusions
where a cylinder or motor is driven by a constant-displacement pump. In
the recirculating mid-position, hydraulic fluid is discharged to the tank at
almost zero pressure, which means that the temperature rise remains
small. The disadvantage of using this valve is that it is not possible to
operate any further hydraulic circuits.
In the case of valves with a closed position for connection P, the pump
delivery is discharged to the tank at maximum system pressure, which
results in pronounced heating of the fluid (= energy loss).

C-32
Solution 7

C-33
Solution 8
Cold-store door

C-34
Solution 8
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety valve


C-35
Solution 8

0Z2, 0Z3 2 Pressure gauge
0V3 1 One-way flow -return valve, adjustable
0Z4 1 Diaphragm accumulator
1A 1 double-acting Cylinder
7 Hose line
3 Branch tee
After the circuit has been assembled and checked, the accumulator Solution description
should first be switched off and the pressure relief valve 0V1 fully
opened. Now switch on the hydraulic power pack and set the system
pressure to 50 bar. The accumulator can now be charged. Allow the
cylinder to advance and retract several times and then switch off the
hydraulic power pack. It is possible to advance and retract the cylinder
several times more by actuating the 4/2-way valve 1A. Following this,
the accumulator pressure will fall slowly, as indicated by the pressure
gauge 0V3. Be sure to switch off and depressurise the accumulator be-
fore dismantling the circuit!
System pressure Opening Closing Evaluation
20 bar 2x 1x
50 bar 4x 3x

C-36
Solution 8
Conclusions Without the accumulator fitted, the door will remain in its instantaneous
position after a power failure and it will no longer be possible to move it.
This diaphragm accumulator allows the door to be opened 2 x and
closed 1 x with a system pressure of 20 bar and opened 4 x and closed
3 x with a system pressure of 50 bar. The higher the hydraulic pressure
with which the accumulator is charged, the more times the door can be
opened and closed.
Design In the case of a diaphragm accumulator, a diaphragm is clamped into

place in the pressure vessel to act as a divider between the hydraulic
fluid and the gas cushion (nitrogen). A gas valve is fitted at the top to
allow the accumulator to be pressurised with gas via a filling device. A
closure head is fitted to the diaphragm or a shut-off valve to the gas inlet
to prevent the diaphragm from creeping into the gas inlet as the gas is
discharged and becoming damaged. The accumulator used here has an
3
initial gas pressure rating of 10 bar and a nominal volume of 0.32 cm .
All accumulators must be fitted with a lead-sealed safety pressure relief
valve and a shut-off valve, as appropriate to their capacity.
Mode of operation When hydraulic fluid is forced into the accumulator, this causes a corre-
sponding reduction in the volume of the gas. At the same time, the
pressure in the gas cushion rises until the gas and hydraulic fluid are at
the same pressure. When the fluid pressure falls, the gas forces fluid
back into the hydraulic system. A non-return valve must be fitted up-
stream of the pump to prevent stored fluid from being discharged via the
pump when this is switched off. Comprehensive manufacturers’ tables
are available for use when sizing accumulators.In addition to diaphragm
and bladder accumulators, piston accumulators are also available if
large capacities are required.
Examples Accumulators are used for the following:

of applications
Compensation for leakage losses
Energy reserve in emergencies
Compensation for peaks in flow rate demand
Cushioning of switching jolts

C-37
Solution 9
Rotary machining station
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

C-38
Solution 9

0Z2, 1Z1, 1Z2, 1Z3, 1Z4 5 Pressure gauge
0V1, 1V4 2 Pressure relief valve
1V1 1 4/3-way valve, manually operated
1V3 1 2-way flow control valve
1V2, 1V5 2 Non-return valve
1A 1 Cylinder
12 Hose line
6 Branch tee
1 Stop-watch
Solution description Assemble and check the circuit. Close the shut-off valve 0V2 and set
the desired pressure by means of the pressure relief valve 0V1.
Now open the pressure relief valve 1V4 and the shut-off valve 0V2.
Open the flow control valve approx. 2 turns so that the piston rod moves
into its forward end position in approx. 5 sec., when the 4/3-way valve is
actuated. Do not make any further changes to the flow control valve
setting. As soon as the piston rod reaches the forward end position with
the 4/3-way valve actuated, use the pressure relief valve 0V1 to set the
values in table 1 (check these on the pressure gauge 1Z1).
The pressure as indicated on the pressure gauge 1Z4 must be set dur-
ing the advance stroke, using the pressure relief valve 1V4. Flow is not
possible through the flow control valve and pressure relief valve in the
opposite direction. The two non-return valves 1V2 and 1V5 are fitted to
allow these to be bypassed.
In the case of settings p1Z1 = 50 bar and p1Z4 = 40 bar (in tables 1 and 2),
the pump requires approx. 1-2 sec. to build up a counter pressure of
40 bar. The time should therefore be measured not from the moment
the 4/3-way valve is actuated but from the moment the piston rod starts
to move. In the case of table 2, the specified values of 50 bar cannot be
fully reached due to the resistances present.

C-39
Solution 9
p1Z1 = Pressure upstream of flow control valve Evaluation

p1Z3 = Pressure downstream of flow control valve
p1Z1 p1Z3 p1Z4 t→ Fluctuating

inlet pressure
50 bar 7 bar 10 bar 4s

outlet pressure
Even with modified pressures at the inlet and outlet, the piston advance- Conclusions
stroke times remain constant. The flow rate will be inadequate only if the
supply pressure is too low.
The pressure intensification effect becomes noticeable with higher
counter pressure; the advance-stroke speed falls only when the counter
pressure reaches approx. 70 bar. The pressure reached on the piston
rod side is then 48 bar.
This exercise is also suitable for practice with fault-finding. If the non-
return valves are installed incorrectly, the piston rod will not retract. The
cause of this can be identified by systematic observation of the pres-
sure-gauge readings.

C-40
Solution 9

C-41
Solution 10
Painting booth

C-42
Solution 10
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety valve


1S 1 Flow sensor
1V3 2 Throttle valve
6 Hose line
2 Branch tee

C-43
Solution 10
Assemble and check the circuit in accordance with the circuit diagram. Solution description
Fully open the pressure relief valves 0V1 and 1V1 and close the shut-off
valve 0V2. Open the flow control valve 0Z2 approx. 2 turns.The hydrau-
lic power pack can now be switched on. The system pressure of 50 bar
required for the exercise should be set on the pressure relief valve 0V1
and checked on the pressure gauge 0Z2.
Now open the shut-off valve 0V2. If the pressure gauge 1Z1 shows less
than 50 bar, re-adjust the pressure relief valve 0V1 slightly. The flow
control valve 0V2 can now be set to the desired flow rate of 2 l/min.
The load pressure should be varied by means of the pressure relief
valve 1V1 in accordance with the specified values. For the second half
of the measurements, the pressure relief valve 1V1 should be fully
opened and the system pressure varied by means of the pressure relief
valve 0V1. The system pressure/flow rate characteristic for the flow
control valve can then be plotted.
If the same exercise is carried out using a throttle-type flow control
valve, the differences will be readily apparent in the tables of values.
p1Z1 = Pressure upstream of valve Evaluation

p1Z2 = Pressure downstream of valve
qFCV = Flow rate through flow control valve
qTV = Flow rate through throttle valve

load pressure
50 bar 20 bar 2 l/min 1.8 l/min
50 bar 50 bar 1.2 l/min 0.1 l/min

C-44
Solution 10
Fluctuating inlet p1Z1 p1Z2 qFCV qTV

pressure
10 bar 10 bar 1.5 l/min 0.4 l/min
Flow control valve

characteristic
Conclusions Only the flow control valve offers a suitable means of setting a constant
speed with different pressures. In the case of the throttle valve, the flow
rate varies as a function of pressure. Reason: In the case of the flow
control valve, the built-in pressure compensator keeps the pressure dif-
ference constant. This gives a constant flow rate, which can then be
adjusted with a throttle valve. Operation of the pressure compensator
does, however, require a certain minimum pressure. The throttle valve is
a simple restrictor, which produces a flow rate as a function of the pres-
sure difference.

C-45
Solution 11
Embossing machine
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety valve


C-46
Solution 11

0Z2, 1Z1, 1Z2, 1Z3, 1Z4 5 Pressure gauge
1V2 1 One-way flow control valve
14 Hose line
4 Branch tee
1 Stop-watch
Solution description Once the circuit has been assembled and checked, close the shut-off
valve 0V2 and set a pressure of 50 bar, using the pressure relief valve
0V1. Open the pressure relief valve 1V3 and the shut-off valve.
Now adjust the one-way flow control valve 1V2 in such a way that the
piston rod reaches its forward end position in approx. 5 sec. after the
4/2-way valve 1V1 is reversed.
Do not make any further changes to the setting of the one-way flow
control valve. The pressure specified in table 1 of 10 bar, as indicated by
the pressure gauge 1Z4, can be set only during the advance stroke,
using the pressure relief valve 0V1. The pressure p1Z1 should be set by
means of the pressure relief valve 0V1 as soon as the 4/2-way valve is
reversed and the piston rod has reached its forward end position.

C-47
Solution 11
p1Z1 = Pressure upstream of one-way flow control valve Evaluation

p1Z3 = Pressure downstream of one-way flow control valve

inlet pressure
30 bar 9 bar 10 bar 7.5 s
20 bar 9.5 bar 10 bar 12.5 s
10 bar 9.8 bar 10 bar 57 s

outlet pressure
50 bar 15 bar 20 bar 4.5 s
50 bar 28 bar 40 bar 6.5 s

C-48
Solution 11
Conclusions In the case of a circuit with a throttle valve, the travel speed falls both as
the inlet pressure is reduced and as the counter pressure increases.
In the case of the circuit with a flow control valve (exercise 9), the travel
speed remains constant.
Reason: The throttle valve varies only the cross-section of the line
through which flow passes. The flow rate produced is dependent on the
difference in the pressures upstream and downstream of the restriction.
The flow rate through the throttle valve is thus dependent on pressure,
in fact on both the supply and load pressures. The flow control valve
incorporates a pressure compensator which maintains the internal pres-
sure difference at a constant value. The flow rate is thus not dependent
on the supply and load pressures.

C-49
Solution 12
Surface grinding machine
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety valve


C-50
Solution 12

0V3 1 2-way flow control valve
7 Hose line
4 Branch tee
1 Stop-watch
Solution description Assemble and check the circuit. Close the shut-off valve 0V2 and the
flow control valve 0V3. Now switch on the hydraulic power pack and set
a system pressure of 50 bar by means of the pressure relief valve 0V1.
Now open the shut-off valve 0V2 and also open the flow control valve
until the piston rod advances. The measurements can now be carried
out.
Evaluation p1Z1 = Pressure on piston side of cylinder

p1Z2 = Pressure on annular piston side of cylinder
t→ = Cylinder advance-stroke time approx. 4 s
Values table Direction p1Z1 p1Z2 t
Advance stroke 3.5 bar 5 bar 4.31 s
Return stroke 0 bar 4.5 bar 6.57 s

C-51
Solution 12
Cylinder dimensions:
2
2
Annular piston area: APR = 1.2 cm
Cylinder stroke: s = 0.2 m
A PN 2 cm 2
Area ratio: α= = = 167
. ≈ 17
.
A PR 12. cm 2
t adv 4.31 s
Time ratio: = = 0.656
t ret 6.57 s
F1 A ⋅p 2 cm 2 ⋅ 3.5 bar
Force ratio: = PN 1Z1 = = 12
. <α
F2 A PR ⋅ p 1Z 2 . cm ⋅ 5 bar
12
Flow rate during advance stroke:
s 20 cm
Piston side: qPN = A PN ⋅ = 2 cm 2 ⋅
t adv 4.31 s
cm 3 cm 3 l
qPN = 9.28 = 557 ≈ 0.6
s min min
s 20 cm
Annular piston side: qPR = A PR ⋅ = 12
. cm 2 ⋅
t adv 4.31 s
cm 3 cm 3 l
qPR = 5.57 = 334 ≈ 0.3
s min min
Flow rate during return stroke:
s 20 cm
Annular piston side: qPR = A PR ⋅ = 12
. cm 2 ⋅
t ret 6.57 s
cm cm 3 l
qPR = 3.65 = 219 = 0.2 = qFCV
s min min

C-52
Solution 12
Conclusions If the same pressure acts on a larger area (APN), this produces a larger
force (F1).
Mathematical proof:
Given p 1Z1 = p 1Z 2
F1 F
and p 1Z1 = und p 1Z 2 = 2
A PN A PR
F1 A PR
we optain = =α
F2 A PR
it follows: F1 = α ⋅ F2
Since α > 1, F1 > F2, and the cylinder advances.
The lower travel pressure p1Z1 acts on the larger area APN, producing a
greater force F1. Only when the ratio of travel pressure to back pressure
becomes equal to the area ratio a is an equilibrium of forces achieved,
causing the piston to stop.
Mathematical proof:
F1 A ⋅p
= PN 1Z1
F2 A PR ⋅ p 1Z 2
Für F1 = F2
p 1Z 2 A
gilt = PN = α
p 1Z1 A PR
p 1Z 2
As long as < α , the piston will advance.
p 1Z1

C-53
Solution 12
The available cylinder force is:
F = F1 − F2 = (A PN ⋅ p 1Z1 ) − (A PR ⋅ p 1Z 2 )
F = (2 cm 2 ⋅ 3.5 bar) − (12

. cm 2 ⋅ 5 bar)
F = (7 kp − 6 kp) = 1 kp = 10 N
A comparison of a simple cylinder control circuit and a differential circuit

reveals the following differences:
System Simple cylinder control cir- Differential circuit General comparison

cuit
1. Advance-stroke Adjustable on FCV Greater than set on FCV

speed ≈ qFCV > qFCV
vadv
2. Return-stroke Greater than Less than advance

speed advance-stroke speed stroke speed
vret > vadv < vadv (with α < 2)
3. Advance-stroke Adjustable on FCV Less than set on FCV

time ≈ qFCV < qFCV
tadv
4. Return-stroke time Less than Greater than

tret Advance-stroke time Advance-stroke time
< tadv > tadv (with α < 2)
With an area ratio of α = 2, the advance-stroke and return-stroke

speeds are the same.
Reason: The flow rate required on the piston side is double that neces-
sary on the piston rod side. During the advance stroke, this flow rate is
supplied from the pump and the annular piston side. During the return
stroke, only supply from the pump is available. The return-stroke speed
is produced by this. The advance-stroke and return-stroke speeds can
be the same only when the area ratio α = 2.

C-54
Solution 12
Below is the mathematical proof of this:
Simple cylinder control APN APR APN APR

circuit and differential circuit
vadv vadv
qPN qPR vPN qPR
qFCV qFCV
Basic equations:
A PN
Area ratio: α=
A PR
q
Speed: v=
A
s
Travel time: t=
v

C-55
Solution 12
1. Advance-stroke speed
qPN q
Simple cylinder control circuit: v adv = = FCV
A PN A PN
qPN
With differential circuit: v adv =
A PN
Flow rate on piston side: qPN = qFCV + qPR
qPN A
Given = PN = α
qPR A PR
1
we obtain: qPR = ⋅ qPN
α
1
It follows: qPN = qFCV + ⋅ qPN
α
1
qPN ⋅ (1 − ) = qFCV
α
α −1
qPN ⋅ = qFCV
α
α
qPN = ⋅ qFCV
α −1
The advance-stroke speed with a differential circuit is thus:
α q
Vadv = ⋅ FCV
α − 1 A PN
qFCV
For α = 2 Vadv = 2 ⋅ ,
A PN
and is thus twice as high as with the simple cylinder control circuit.

C-56
Solution 12
2. Return-stroke speed
Simple cylinder control circuit:
qPR q q
v ret = = FCV = α ⋅ FCV
A PR A PR A PN
v ret = α ⋅ v adv
Since α > 1, v ret > v adv
With differential circuit:
qPR q q
v ret = = FCV = α ⋅ FCV
A PR A PR A PN
qFCV
α⋅
v ret A PN
= = α −1
v adv α qFCV
⋅
α − 1 A PN
v ret = (α − 1) ⋅ v adv
For α = 2, v ret = v adv

C-57
Solution 12
3. Advance-stroke time
s
In general:: t=
v
s A PN ⋅ s
Simple cylinder control circuit:: t adv = =
qFCV qFCV
A PN
s α − 1 A PN ⋅ s
With differential circuit:: t adv = = ⋅
α qFCV α qFCV
⋅
α − 1 A PN
1 A PN ⋅ s
With α = 2, t adv = ⋅
2 qFCV
4. Return-stroke time
s A ⋅s
Simple cylinder control circuit: t ret = = PN
q α ⋅ qFCV
α ⋅ FCV
A PN
s A ⋅s
With differential circuit:: t ret = = PN
q α ⋅ qFCV
α ⋅ FCV
A PN
A PN ⋅ s
t ret α ⋅ qFCV 1
= =
t adv α − 1 A PN ⋅ s α − 1
⋅
α qFCV
t ret 1
=
t adv α − 1
With α = 2, t ret = t adv

C-58
Solution 12
The evaluation can thus be expressed as follows:
Mathematical comparison System Simple cylinder control circuit Differential circuit
1. Advance-stroke qFCV α qFCV

speed ⋅
A PN α − 1 A PN
vadv
2. Return-stroke speed α ⋅ v adv (α − 1) ⋅ v adv

vret
3. Advance-stroke time A PN ⋅ s α − 1 A PN ⋅ s
tadv ⋅
qFCV α qFCV
4. Return-stroke time 1 1
⋅ t adv ⋅ t adv
tret α α −1
Alternative solutions giving identical advance-stroke and return-stroke

speeds:
Differential circuit with

4/3-way valve with
special mid-position
Equal-speed cylinder
controlled by
4/2-way valve

C-59
Solution 13
Drilling machine

C-60
Solution 13
Practical assembly,
hydraulic
System
pressure
p = 50 bar
(5 MPa)
Pump safety valve


C-61
Solution 13

0Z2, 1Z1, 1Z2, 1Z3 4 Pressure gauge
1V2 1 Pressure regulator
1V5 1 One-way flowcontrol valve
15 Hose line
5 Branch tee

C-62
Solution 13
Solution description In the first task in the exercise, the travel pressures are measured; the
inlet pressure can be set to 15 bar (as shown on p1Z2) only after the pis-
ton has reached its forward end position or is opposed by a resistance.
This is demonstrated by task 2 (piston in forward end position). This
task also shows that the pressure regulator maintains a pressure of
15 bar even without through-flow.
The valves 1V3 and 1V4 provide a bypass of the pressure regulator to
allow a faster return stroke to be achieved.
If the advance stroke is opposed by a resistance, as in task 3, a flow
pressure of only 12 - 15 bar is achieved, despite the system pressure of
50 bar. By closing the throttle valve 1V5, it is possible to increase the
counter pressure until the pressure gauge p1Z2 shows 15 bar; the piston
will then stop, i.e. the pressure regulator will close.
In task 5, it is demonstrated that increased counter pressure during the
return stroke causes the valve to the tank to open, resulting in only the
set pressure of 15 bar being attained. The piston can be pushed into the
retracted end position. With the piston in this position, as in task 6, the
15 bar pressure is initially maintained. Due to internal leakage within the
valve, the pressure then falls below 15 bar, causing the pressure regula-
tor to switch from A - T to P - A. As no pump delivery is reaching the line
to the pressure regulator via the 4/3-way valve, the pressure falls to
0 bar.
In practice, a pressure relief valve with bypass must be used in place of

the one-way flow control valve 1V5. This prevents the high pressures
which would arise upstream of the one-way flow control valve due to
pressure intensification during the advance stroke of the piston. A one-
way flow control valve has been used in this case to simplify the circuit
configuration. Excessive pressures cannot arise in this case due to the
fact that the system is being operated with reduced pressure.

C-63
Solution 13
Measured are: Evaluation

p1Z1 = Pressure upstream of pressure regulator
p1Z2 = Pressure upstream of cylinder
p1Z3 = Pressure downstream of cylinder
Cases of examination:
1. Piston advance stroke
2. Piston advanced to end position with setting p1Z2 = 15 bar.
3. Piston advance stroke with counter pressure setting, p1Z3 = 20 bar.
4. Piston advanced to end position
5. Piston advance stroke with shut-off valve closed
6. Piston advanced to end position with shut-off valve closed
Cases of examination p1Z1 p1Z2 p1Z3 Advance stroke
1. Advance stroke 5 bar 2 bar 1 bar
2. End position 50 bar 15 bar 0 bar
3. Advance stroke with counter pressure 49 bar 13 bar 20 bar
5. Advance stroke with pressure regulator 49 bar 14 bar 20 bar
Cases of examination p1Z1 p1Z2 p1Z3 Return stroke
1. Return stroke 4 bar 7 bar 16 bar
3. Return stroke with counter pressure 6 bar 10 bar 18 bar
5. Return stroke with pressure regulator 0 bar 26 bar 46 bar

C-64
Solution 13
Conclusions Pressure regulators are used in cases when a secondary circuit with a
constant but lower pressure is required in addition to a primary circuit.
Note that increased pressures occur which act on port A of the pressure
regulator. These pressures must be discharged to the tank.

C-65
Solution 14
Bulkhead door
Circuit diagram, hydraulic,

without counter-holding
System
pressure
p = 50 bar
(5 MPa)
Pump safety
valve
pmax = 60 bar
(6 MPa)

C-66
Solution 14
Practical assembly,
hydraulic,
with counter-holding
In inlet line
p = 10 bar
(1 MPa)
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

C-67
Solution 14

1V1 1 4/2-way valve
1V2 1 One-way flow control valve
12 Hose line
4 Branch tee
1 Stop-watch
Assemble and check the circuit. Mount the cylinder 1A on the profile in Solution description
such a way that it can advance downwards. First close the shut-off valve
0V2. Switch on the hydraulic power pack and then use the pressure re-
lief valve 0V1 to set a system pressure of 50 bar. Open the shut-off
valve and adjust the pressure relief valve 1V2 in such a way that the
piston rod advances in approx. 5 sec. The throttle valve setting should
be retained while manipulating the circuit using the weight 1Z3, with
counter-holding provided by the pressure relief valve 1V3. For the return
stroke, a non-return valve 1V4 is required as a bypass for the pressure
relief valve. After the measurements have been completed, first remove
the weight and then retract the cylinder. Now depressurise the circuit by
closing the shut-off valve and then opening the pressure relief valve
1V3. Dismantle the circuit only when the pressure has fallen to zero, as
shown by the pressure gauge 1Z2.

C-68
Solution 14

Values table With load and counter-holding p0Z2 p1Z1 p1Z2 t→
Without load with counter-holding 50 bar 0 bar 0 bar 5.0 s

With load without counter-holding 50 bar 0 bar 0 bar 0.8 s
With load and counter-holding 50 bar 2 bar 10 bar 4.6 s
Without load with counter-holding 50 bar 7 bar 10 bar 5.3 s
Conclusions The travel time becomes shorter as the load increases.

Reason: The piston is pulled out by the load. Without counter-holding,
the movement is uncontrolled and jerky. A constant advance-stroke
speed is obtained only with counter-holding. The generation of a counter
pressure clamps the piston hydraulically. The travel and back pressures
remain constant, which means that the travel speed also remains con-
stant.
A circuit with counter-holding is advisable both with and without a load. It

is also possible to adjust the counter-holding to suit the load.

C-69
Solution 15
Ferry loading ramp
Circuit diagram, hydraulic,

with counter-holding
and flow control valve
in inlet line
In Inlet line
p = 10 bar
(1 MPa)
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

C-70
Solution 15
Practical assembly,
hydraulic,
with flow control valve
in outlet line
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

C-71
Solution 15

1V1 1 4/3-way valve
13 Hose line
4 Branch tee
1 Stop-watch
Assemble and check the circuit. Mount the cylinder 1A on the profile Solution description
plate in such a way that it can advance downwards. First close the shut-
off valve 0V2. Switch on the hydraulic power pack and then use the
pressure relief valve 0V1 to set a system pressure of 50 bar. Open the
shut-off valve and adjust the pressure relief valve 1V3 in such a way that
the piston rod advances in approx. 5 sec. The flow control valve setting
should be retained throughout the series of measurements. Only the
circuit should be modified. Dismantle the circuit only when the pressure
has fallen to zero, as shown by the pressure gauge 1Z2.

C-72
Solution 15

Flow control valve With load and counter-holding p0Z2 p1Z1 p1Z2 t→
in inlet line
Without load without counter-holding 50 bar 0 bar 0 bar 5s
With load without counter-holding 50 bar 0 bar 0 bar 0.6 s
With load and counter-holding 50 bar 3 bar 10 bar 5s
Without load with counter-holding 50 bar 8 bar 10 bar 5s
Flow control valve Load p0Z2 p1Z1 p1Z2 t→

in outlet line
Without load 50 bar 48 bar 77 bar 5s
With load 50 bar 48 bar 84 bar 3.1 s
Conclusions Without counter-holding, the piston rod is pulled out by the load. It ad-
vances jerkily. With counter-holding, the same speed is achieved with
and without a load. If, however, the flow control valve is installed in the
outlet line to provide counter-holding, very high pressures will occur on
the outlet side. This is often unacceptable in practice.
A suitable circuit is thus one with a flow control valve in the inlet line and
counter-holding by means of a pressure relief valve in the outlet line.

C-73
Solution 16
Skip handling
Practical assembly,
hydraulic
p = 30 bar p = 50 bar
(3 MPa) (5 MPa)
System
pressure
p = 50 bar
(5 MPa)
Pump
safety valve
pmax = 60 bar
(6 MPa)

C-74
Solution 16

0V, 1V3, 1V4 3 Pressure relief valve
10 Hose line
4 Branch tee
Solution description Assemble the control circuit in accordance with the circuit diagram. En-
sure that the non-return valves are installed correctly. Open the pres-
sure relief valves fully. If a sufficient number of pressure relief valves are
not available, the system pressure can also be set on the pressure relief
valve of the hydraulic power pack.
Check the circuit and then switch on the hydraulic power pack. Now set
the system pressure to 50 bar. When the directional control valve 1V1 is
actuated, the cylinder advances and retracts at maximum speed. The
travel motion can be slowed down by closing the two pressure relief
valves 1V3 and 1V4. Adjustment is carried out using the pressure relief
valve in the outlet line in each case. The non-return valves 1V2 and 1V5
are used to bypass the pressure relief valves fitted in each inlet line. The
counter-holding pressures are shown on the pressure gauges 1Z1 and
1Z2.
If the non-return valves are installed incorrectly, the travel speed will not
change even when the pressure relief valves are closed. With the pres-
sure relief valves fully closed, the cylinder will no longer retract due to
the pressure intensification effect present.
Before the circuit is dismantled, the pressure relief valves must once
again be fully opened to ensure that no pressure is trapped.

C-75
Solution 16
Hydraulic clamping on both sides is provided by two counter-holding Conclusions

circuits with pressure relief valves. A non-return valve is required as a
bypass in each direction. Take account of the cylinder area ratio when
setting the pressure.
In practice, skip handling is controlled using proportional valves. Dy- Remark

namic adjustment of the proportional valves allows better control of fast
and slow travel motions.

C-76
Solution 16

C-77
Solution 17
Bonding press
Practical assembly,
hydraulic
With 3-way pressure regulator With pressure relief valve
p = 30 bar p = 30 bar
(3 MPa) (3 MPa)
p = 50 bar p = 50 bar
(5 MPa) (5 MPa)
pmax = 60 bar (6 MPa) pmax = 60 bar (6 MPa)

C-78
Solution 17

0V, 1V4 2 Pressure relief valve
1V2 1 Pressure regulator
7 Hose line
5 Branch tee
Solution description In the case of the circuit with the pressure regulator, the shut-off valve
must be opened to retract the piston rod. Due to the pressure intensifi-
cation effect, the system pressure of 50 bar is not sufficient to open the
pressure regulator from A to T.
Conclusions If a pressure relief valve is fitted in the bypass, the overall system pres-
sure will fall to 30 bar during the advance stroke. If a pressure regulator
is used, the system pressure of 50 bar is maintained, and only the cylin-
der is supplied with the reduced pressure of 30 bar. This allows further
actuators to be supplied with full system pressure by the same hydraulic
power pack. Check, however, that the pump delivery is sufficient for this.
The pressure relief valve gives an advantage in this application, since, in
the case of long standstill periods with the directional control valve ac-
tuated, the pump need only develop the set pressure of 30 bar.

C-79
Solution 18
Assembly device
Practical assembly,
hydraulic
p = 30 bar p = 20 bar
(3 MPa) (2 MPa)
q = 1 l/min
p = 50 bar
(5 MPa)
p = 60 bar
(6 MPa)

C-80
Solution 18
Displacement-step diagram Components Time
Step
Description Desig- Signal
nation
4/3-way-valve *
Cylinder
Motor
* 4/3-way-valve Switching position a:
Switching position 0:
Switching position b:

C-81
Solution 18

0V1, 1V2, 1V4 3 Pressure relief valve
1A1 1 Cylinder, double-acting
1A2 1 Hydromotor
1Z1, 1Z2 2 Pressure gauge
16 Hose line
7 Branch tee
1 Flow sensor
Before assembling the circuit, set the flow control valve to a flow rate of Solution description
1 l/min. When assembling the circuit, ensure that the non-return valves
are installed correctly, since otherwise pressure may become trapped. If
a sufficient number of pressure relief valves is not available, the system
pressure can be set on the pressure relief valve of the hydraulic power
pack.
Once the circuit has been assembled and checked, switch on the hy-
draulic power pack. The shut-off valve should be closed at this time. The
system pressure of 50 bar can now be set on the pressure relief valve
0V1. The two other pressure relief valves should be closed.
When the 4/3-way valve is actuated, fluid will first flow to cylinder 1A1,
and the piston of this will advance. Motor 1A2 will begin to rotate only
when the pressure relief valve 1V4 is opened. The return stroke is initi-
ated by reversing the 4/3-way valve. The motor will then stop. A pres-
sure will build up at the pressure relief valve 1V2. Cylinder 1A1 will
retract when the pressure relief valve 1V2 is opened.

C-82
Solution 18
Conclusions The most important steps in commissioning are as follows:
1. Presetting of flow rate
2. Assembly of circuit
3. Closing the pressure relief valves
4. Checking the circuit
5. Switching on the hydraulic power pack
6. Adjusting the pressure relief valves during the operation of the control
circuit

C-83
Solution 19
Calculation for an assembly device
Evaluation
Schematic diagram
π 2
Piston force: F1 = A PN ⋅ p 1 = ⋅ D ⋅ p1
4
π
F1 = ⋅ 50 2 mm 2 ⋅ 50 bar
4
π kp
F1 = ⋅ 50 2 mm 2 ⋅ 50
4 cm 2
π 50 2 mm 2 ⋅ 50 kp
F1 = ⋅
4 100 mm 2
F1 = 98175
. kp = 9817.5 N
F1 = 9.8 kN

C-84
Solution 19
π
Counter force: F2 = A PR ⋅ p 2 = ⋅ (D 2 − d 2 ) ⋅ p 2
4
π
F2 = ⋅ (50 2 − 25 2 ) mm 2 ⋅ 6 bar
4
π kp
F2 = ⋅ (50 2 − 25 2 ) mm 2 ⋅ 6
4 cm 2
π 1875 mm 2 ⋅ 6 kp
F2 = ⋅
4 100 mm 2
F2 = 88.36 kp = 883.6 N
F2 = 0.9 kN
Press-fitting force: F = F1 − F2 = 9.8 kN − 0.9 kN
F = 8.9 kN
π 2
⋅D ⋅ s
V A ⋅s 4
Press-fitting time: t = = PN =
q q q
π 50 2 mm 2 ⋅ 250 mm
t= ⋅
4 l
5
min
π 5 2 cm 2 ⋅ 25 cm
t= ⋅
4 5000 cm 3
60 s
π 625 cm 3 ⋅ 60 s π 625 ⋅ 60 s
t= ⋅ = ⋅
4 5000 cm 3 4 5000
t = 5.89 s ≈ 6 s

C-85
Solution 20
Tipping container
Practical assembly,
hydraulic
p = 50 bar
(5 MPa)
pmax = 60 bar
(6 MPa)

C-86
Solution 20
Circuit diagram, electrical
S1 = “Up” pushbutton
S2 = “Down” pushbutton
Components list, Item no. Qty. Description

hydraulic
0Z 1 Hydraulic power pack
1V1 1 4/3-way solenoid valve
1V2 1 Non-return valve, hydraulically piloted
6 Hose line
2 Branch tee
Components list, Item no. Qty. Description

elektrisch
1 Signal input unit
1 Relay, 3-fold
1 Cable set
1 Power supply unit

C-87
Solution 20
A piloted non-return valve is used to protect the tipping container against Solution description
undesired lowering. A 4/3-way valve with a mid-position in which A, B
and T are connected and P is closed is used in order to ensure that the
non-return valve closes when the electrical control circuit is switched off.
This 4/3-way valve relieves ports A and B in its mid-position.
Once the electrical and hydraulic circuits have been assembled and
checked, actuate push-button S1. This causes the cylinder piston rod to
travel to its forward end position (filling position). When the push-button
S1 is released, a spring force causes the 4/3-way valve to switch to its
mid-position. The load acting on the piston rod now causes the pilot-
operated non-return valve to close, which prevents the piston rod from
being pushed back. When the push-button S2 is actuated, the 4/3-way
valve reverses. The pressure which builds up in the line from port B of
the valve causes the non-return valve to open and the piston rod of the
cylinder travels into its retracted end position (emptying position).
The two push-buttons S1 and S2 each actuate one normally-open and
one normally-closed contact, which are connected together in such a
way that no movement occurs if the push-buttons are actuated simulta-
neously.
It is also possible to carry out these exercises using the 4/3-way valve
with recirculating mid-position which is included in the equipment set.
Due to the inherent characteristics of this valve, internal leakage losses
can occur which will cause the piloted non-return valve to close.
The electrical circuit diagram incorporates an interlock between current Conclusions

paths 1 and 2. This ensures that the control circuit will work correctly
even in the case of operator error.

C-88
Solution 20

Festo Hydraulics Workbook Basic Level TP501 204

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Learning System for Automation

Order no.: 094468

© Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2001

TP501 · Festo Didactic

Mounting frame Fig. 1:

TP501 • Festo Didactic

The modular structure of the Learning System permits applications to be

The hardware consists of industrial components and installations,

TP501 • Festo Didactic

Latest information about the technology package TP501.

New in Hydraulic 2000:

TP501 • Festo Didactic

TP501 • Festo Didactic

TP501 • Festo Didactic

Exercise 11: Embossing machine

TP501 • Festo Didactic

TP501 • Festo Didactic

TP501 • Festo Didactic

We recommend the following for the practical execution of the exer-

TP501 • Festo Didactic

This workbook provides knowledge of the physical interrelationships and

The following technical equipment is required for safe operation of the

The theoretical background is described in the “Hydraulics Basic Level”

TP501 • Festo Didactic

1. The hydraulic power pack and electrical power supply must be

5. Before dismantling the circuit, ensure that pressure in hydraulic com-

Couplings must be connected and disconnected only under

TP501 • Festo Didactic

The operating pressure should not exceed 60 bar (6 MPa).

 In the case of double-acting cylinders, the pressure intensification

 If connections are detached under pressure, the non-return valve in

Throttle valve Hose Shut-off valve

TP501 • Festo Didactic

 It is frequently necessary when assembling a control circuit to modify

2/2-way valve 3/2-way valve Fig. 4:

4/2-way valve 4/2-way valve Fig. 5:

Circuit diagram Practical assembly Fig. 6:

TP501 • Festo Didactic

Flow rate sensor

The flow rate sensor consists of:

Fig. 8: q Hydraulic n Tacho- V Universal q

External power supply

TP501 • Festo Didactic

TP501 • Festo Didactic

List of training aims Exercise Training aims

1 Drawing a pump characteristic.

TP501 • Festo Didactic

Equipment set for “Hydraulics Basic Level”

TP501 • Festo Didactic

Additional equipment Description Order No. Qty.

Accessories Description Order No. Qty.

Profile plate, large 159411 1

TP501 • Festo Didactic

Description Symbol Symbols for

One-way flow control valve

Pressure relief valve

Pilot-operated pressure relief valve

Flow control valve

Piloted non-return valve

TP501 • Festo Didactic

In the case of double-acting cylinders, the pressure intensification

If connections are detached under pressure, the non-return valve in

It is frequently necessary when assembling a control circuit to modify

Drawing the hydraulic circuit diagram Problem definition

Drawing the hydraulic circuit diagram Problem definition

To teach the student how to measure flow resistances Training aim

Drawing the hydraulic circuit diagram Problem definition

Drawing the hydraulic circuit diagram Problem definition

Drawing the hydraulic circuit diagram Problem definition