Technical education document

Oil Hydraulics − Basic Technology Textbook

DAIKIN INDUSTRIES, LTD.

Training Dept.
 CONTENTS

Chapter 1 Basis of Oil Hydraulics

1. Overview of oil hydraulics.................................................................................................1
2. Basic structure of oil hydraulic device and JIS symbols....................................................2
3. Basic equations of oil hydraulics .......................................................................................3

Chapter 2 Oil Hydraulic Equipment

1. Actuator............................................................................................................................ 11
2. Hydraulic pump ...............................................................................................................17
3. Pressure control valve ......................................................................................................22
4. Flow control valve ...........................................................................................................28
5. Directional control valve..................................................................................................31

Chapter 3 Hydraulic fluid

1. Hydraulic fluid types........................................................................................................37
2. Viscosity of hydraulic fluid..............................................................................................38
3. Viscosity index (VI) .........................................................................................................38
4. Appropriate working range of hydraulic fluid .................................................................38
5. Compressibility ................................................................................................................40
6. Aeration and influence .....................................................................................................40
7. Water incorporation and influence ...................................................................................40
8. Hydraulic fluid contamination and its effects ..................................................................41
9. Hydraulic fluid and Fire Defense Law.............................................................................41

Chapter 4 Basic Circuit

1. Unload circuit...................................................................................................................42
2. Circuit to control pressure required for hydraulic drive...................................................43
3. Control method of flow control valve..............................................................................44
4. Circuit for controlling high load ......................................................................................46
5. Accelerating circuit
(to produce a speed faster than that available by pump discharge rate) ...........................48
6. Circuit for sequential operation of cylinder .....................................................................50
7. Circuit to maintain back pressure (negative load)............................................................51
8. Position-keeping circuit ...................................................................................................52
9. Brake circuit.....................................................................................................................52
10. Closed circuit ...................................................................................................................53
11. Filter circuit for hydraulic fluid........................................................................................54
 Chapter 1

Basis of Oil Hydraulics

1. Overview of oil hydraulics
“Oil hydraulics” is a term for power-converting or power-transmitting systems and devices that actuate hydraulic
cylinders, hydraulic motors and such by controlling three elements (i.e. pressure, flow rate and direction) of oil
discharged from a hydraulic pump while the systems and devices provide turning force to the hydraulic pump.
Making a good use of the oil characteristics in such a manner that the functions required for a task are fully
exploited collectively means utilization of hydraulics. The hydraulics application field has been greatly expanding
as the demands for automation and labor-saving have increased. The hydraulic technologies have made
remarkable progress and development.

(1) Applications of oil hydraulics

Typical applications include tasks that require linear motion, rotary motion, loading power, speed
adjustment, and such.
Construction equipment: Bulldozer, Excavator, truck crane
Transporting equipment: Forklift, dump truck, cement mixer truck
Vessel deck machinery: Winch, steering engine
Machine tool: Lathe, miller, driller, machining center
Steel machinery: Shearing machine, coil winding/rewinding machine
Metal machinery: Casting machine
Synthetic resin: machines for injection molding, extrusion molding and foam molding
Wood working machinery: Hot press, wood transporting vehicle
Bookbinding and printing: Cutting machine, offset printing machine, rotary press
Others: Incinerator, amusement facility, industrial robot

(2) Features of oil hydraulics

[1] Compact in size, big output power
[2] Linear power adjustment is available
[3] Linear speed adjustment is available
[4] Easy to control the direction of motion
[5] Simple overload safety device is applicable
[6] Accumulating of energy is available
[7] Lubricative and rust-preventive working oil prevents moving parts from wearing

−1−
2. Basic structure of oil hydraulic device and JIS symbols
(1) JIS symbols and circuit diagram

Hydraulic cylinder

Flow control valve

Pressure gauge
Directional control valve

Pressure control valve

Hydraulic pump

Air vent
filter
Oil level gauge

Thermometer Filter
Oil tank

断 面section
Cross 回 路circuit
図 diagram ＪＩＳ記号回路図
Circuit diagram using JIS symbols

(2) Sub-assembly of oil hydraulic device

[1] Oil tank
[2] Hydraulic pump
[3] Pressure control valve
[4] Directional control valve
[5] Flow control valve
[6] Actuators (hydraulic cylinder, hydraulic motor)
[7] Others (pressure gauge, filter, air vent filter, thermometer, oil level gauge, etc.)

−2−
3. Basic equations of oil hydraulics
(1) Pascal’s principle
See the illustration to the right. A vertical force W applied on the top of the closed vessel compresses the
fluid confined in the vessel, and the fluid produces a counter-force against the compressive force since a
fluid never changes its cubic volume by nature under compressive pressure.
The counter-force of a fluid is called “pressure”.
Such pressure produced in a fluid has three features as follows. Piston
[1] Where a fluid is in a static state and contacting surfaces, the pressure of the
fluid acts perpendicular to each surface.
Pressure
[2] The pressure at a point in a static fluid acts in every direction with equal
force.
[3] A pressure applied on any part of a static fluid confined in a closed vessel is
transmitted undiminished everywhere at the same time.
(The above features are called “Pascal’s law”.)

(2) Relationship between pressure and force

The term “pressure” used in oil hydraulics is defined as “a magnitude of force (N: Newton) applied on a
unit area of an object (1 m2) and is written as N/m2, which is substituted by Pa (Pascal) as the unit of
pressure.”

In the illustration to the left, F (N) is a force pushing the

right-side piston downward and A (m2) is the
cross-sectional area of the piston. Consequently, the
pressure P produced in the fluid is expressed as P (Pa) =
F (N) / A (m2).
On the Pascal’s principle, the pressure is transmitted
through the piping up to the bottom of the left-side
Selector valve piston with a cross-sectional area of B (m2). Where the
pressure and the load W are balanced, it is expressed as
W (N) = P (Pa) × B (m2).
Tank

The relationship between pressure and force is expressed as follows.

Force (N) Force (N)
Pressure Pressure
(MPa) (MPa)
P= F P= F
A A × 102
Area (mm2) Area (cm2)

[Conversion of pressure]
1Pa = 1 N/m2 = 1 MPa × 10−6 (MPa ⇒ Megapascal)
1 MPa = 1 N/mm2 = 1000000 Pa (MPa and N/mm2 are different in expression but same in
magnitude.)
[Conversion between conventional unit and International System of Units (SI)]
1 kgf/cm2 = 0.0980665 MPa = 0.1 MPa approx.
1 MPa = 10.1972 kgf/cm2 = 10 kgf/cm2 approx.

−3−
(3) Hydraulic cylinder output force (Difference between forces acting on piston area)
When the pressure receiving area of the hydraulic cylinder piston is A1 and P1 is the pressure of the oil
sent into the cylinder for pushing and moving the load rightward, the cylinder output force F is
expressed as follows (where P2 = 0, on the assumption that there is no back pressure).

Output Pressure (MPa)

force (N) Pressure receiving
area (cm2)
F = P1 × A1 × 102
=0

If there is another force (back pressure) acting on the other side of the piston (A2 area) caused by
resistance in the piping or so, the back pressure P2 acts and makes the work of P1 less effective.
Consequently, the amount of the back pressure force has to be subtracted from that of the P1 force.
In this regard, the cylinder output force where a back pressure exists shall be expressed as follows.

Therefore, P1 is given by
Pressure (MPa)
Output force Pressure receiving area (cm2) F + P2 × A 2 × 102
P1 =
(N) A1 × 102
2 2
F = P1 × A1 × 10 − P2 × A2 × 10

Pressure receiving
area (cm2)
Pressure (MPa)

[Exercise 1] In the illustration to the right, the hydraulic

cylinder (A1 = 80 cm2, A2 = 50 cm2) lifts up the
load W while P1 = 5 MPa and P2 = 1 MPa are
produced. Find the force F (N) to lift the load
W up.
[Solution]

−4−
(4) Pipe flow rate and velocity
The term flow rate means the volume of a fluid traveling in a unit of time and is expressed as the
product of a cross sectional area and a flow velocity.

(Volume) (Flow velocity)

(Flow rate)

(Cross sectional area) t: time required for the fluid traveling a distance S
(Distance)

Flow Cross sectional

Q= V (Volume) A (Cross sectional area) × S (Distance) rate area (cm2)
= =A× υ (cm3/s) Q = A ×υ
(Flow rate) t (Time) t (Time) Flow velocity
(cm/s)

* Flow rate Q is expressed in a unit of L/min.

* Flow velocity υ is expressed in a unit of m/s or mm/s.

[Conversion of unit: L/min to cm3/s] [Conversion of unit: cm3/s to L/min]

1000 3 3 60
Q (L/min) × = Q (cm /s) Q (cm /s) × = Q (L/min)
60 1000

[Exercise 2] Find the flow rate (cm3/s) of oil flowing at a velocity of 3 m/s in a pipe whose cross
sectional area is 3 cm2.
[Solution]

[Exercise 3] Find the flow velocity (m/s) of oil being sent at a rate of 30 L/min in a pipe whose cross
sectional area is 10 cm2.
[Solution]

−5−
 [Exercise 4] Determine the inner diameter (mm) of the suction side pipe of a pump with a capacity of
42 L/min where the flow velocity is 0.7 m/s.
[Solution]

In planning of a oil hydraulic system, the first thing to do is selection of devices and tanks that meet the
system capacity, and what’s coming next is selection of connecting piping. A frequent guideline for pipe
size determination is flow velocity.
In general, the range of practical flow velocities of each piping is as follows.
Pump suction line: 0.5 to 1.5 m/s
Pressure line: 1.5 to 5 m/s
Return line: 1.5 to 3 m/s

Reference

Equation to find the pipe inner diameter

Diameter d can be found if area of a circle A is known.

2
A = πd πd2 = 4A d= 4A
4 π

−6−
(5) Inflow required for ensuring piston velocity
As with the case in “(4) Pipe flow rate and velocity”, the equation Q = A x υ is used to find the “inflow”
that enables the piston to move at a velocity υ1. The equation to find “inflow” is provided below.

Pressure receiving
Pressure receiving
area − head side
area − cap side
Inflow Pressure receiving
Piston velocity
(cm3/s) area − cap side (cm2)

Q1 = A1 × υ1

Piston velocity
(cm/s)

Inflow Q1 Outflow Q2

In the above diagram, the outflow Q2 forced out by the A2 area of the piston is also found by the
equation Q = A × υ, and the equation to find Q2 is provided to the right.

Outflow Pressure receiving area

(cm3/s) − head side (cm2)

Q2 = A2 × υ1

Piston velocity
(cm/s)

(6) How to find piston velocity

When Q1 and A1 in the equation Q1 = A1 × υ1 Piston velocity Inflow
are known, υ1 can be found by the equation (cm/s) (cm3/s)
to the right. Q1
υ1 = A1

Pressure receiving
area − cap side (cm2)

[Exercise 5] Find the piston velocity υ1 (cm/s) and outflow Q2 (L/min) where A1 = 80 cm2, A2 = 50
cm2 and Q1 = 24 L/min in the above diagram.
[Solution]

[Exercise 6] See the diagram below. Find the piston velocity υ (cm/s) and outflow Q2 (L/min) when
the piston travels backward, using the values provided.
[Solution]

Q2 L/min Q1 = 24 L/min

−7−
(7) Fluid power
[1] Power is the product of force and velocity.
Force F In the diagram to the left, the equation (in basic unit
Velocity υ [N·m/s]) to express the power L needed for lifting the
load upward by pulling the rope is as follows.
Power Force (N)
(N·m/s)
L=F×υ
Velocity (m/s)

[2] Case of hydraulic system

As with the above, F is the lifting force and υ is the velocity.
Then, where P is the cylinder pressure and Q is the feeding
flow rate, the fluid power LO is expressed as follows.

Q
LO = F × υ = P × A × = P×Q
A

In other words, fluid power is expressed as a product of

pressure and flow rate.

[3] Expressing fluid power in practical units, kW or PS gives following equations.

Where P in MPa and Q in L/min.

Pressure (MPa) Pressure (MPa)

Flow rate (L/min) Flow rate (L/min)

P×Q P×Q
LO = LO =
(kW) 60 (PS) 44.1

[Exercise 7] A pressure of 10 MPa and a flow rate of 20 L/min are needed when a hydraulic cylinder
moves a load. Find the fluid power in kW in this case.
[Solution]

−8−
(8) Torque and number of revolutions of hydraulic motor
T: Output torque (N·m)
N: Actual number of revolutions (min−1) … rpm
p: Difference in pressure between inlet and outlet (available pressure difference) (MPa)
q: Theoretical volume required for one motor revolution (cm3)
(displacement of motor)
Q : Supply oil quantity (cm3/min)
ηT: Mechanical efficiency of motor
ηV: Volumetric efficiency of motor

[1] Motor output torque … Torque is proportional to available pressure difference and displacement

p×q 2π × T
T= ηT Equation to find q q = p×η
2π T

[2] Actual number of revolutions of motor … Number of revolutions is proportional to supply oil
quantity and inversely proportional to displacement.

Q N×q
N = q ηV Equation to find Q Q= ηV

[Exercise 8] Determine the displacement of a hydraulic motor when the required output torque is 100
N·m and the available pressure difference p of the hydraulic motor is 10 MPa.
Then, determine the supply oil quantity needed to run the hydraulic motor up to 1000
min−1.
(where ηT = 90% and ηV = 94%)
[Solution]

−9−
 Exercises

Exercise 1.
In the diagram to the left, F = 2,000 N, A = 20 cm2, and B =
100 cm2.
Find the force that lifts up Piston B.
(10,000 N)

Exercise 2. The pipe inner diameter is 21 mm, and the flow rate is 30 L/min. Find the flow velocity (m/s).
(1.45 m/s)

Exercise 3. Determine the pipe diameter associated with a flow rate of 120 L/min and a flow velocity of 1 m/s.
(50 mm)

Exercise 4. In the hydraulic cylinder diagram below, find the output force F using the values provided.
A = 50 cm2 B = 40 cm2
P1 = 5 MPa P2 = 0.5 MPa (23,000 N)

Exercise 5. In the Exercise-4 diagram, find the outflow Q2 when the inflow Q1 is 30 L/min.
Then, find the piston forward speed as well.
Q2 = 24 L/min
Piston speed = 10 cm/s

Exercise 6. When the pump discharge pressure is 7 MPa and the discharge quantity is 31 L/min, the shaft power
is 4.9 kW.
Find the overall efficiency of the pump. (74%)
[Work on this exercise after learning about hydraulic pumps in Chapter 2.]

Exercise 7. Find the output torque when running a hydraulic motor with displacement q = 150 cm3 at available
pressure difference p = 20 MPa. Where mechanical efficiency ηT = 0.92. (439 N·m)

Exercise 8. Determine the pump discharge quantity when running the hydraulic pump given in Exercise 7 at a
speed of 1,200 min−1. Where volumetric efficiency ηV = 0.96. (187.5 L/min)

− 10 −
 Chapter 2

Oil Hydraulic Equipment

1. Actuator
An actuator, in general, is such equipment that provides linear, oscillating or rotary motion by converting fluid
power from a hydraulic pump into mechanical power.

(1) Types
Single acting type
y Hydraulic cylinder
Double acting type
y Oscillating hydraulic actuator

y Hydraulic motor Gear type

Vane type
Piston type

(2) Hydraulic cylinder

An actuator that uses hydraulic oil pressure to move an operating part in a straight line is called a
hydraulic cylinder.

[1] Types of Hydraulic cylinder

Single acting ram

Single acting single-rod

type
Single acting type

Single acting double-rod

Cylinder types by actuating function

type

Single acting telescope

type

Double acting single-rod

type

Double acting double-rod

type
Double acting type

Double acting
double-piston type

Double acting telescope

type

− 11 −
[2] Single acting cylinder
Single acting cylinder is such that hydraulic oil pressure controls the cylinder motion in one single
direction only while applying a hydraulic oil pressure on one side of the piston. It uses gravity for
the return stroke, which offers an advantage of saving power. In some cases, a spring is used in the
return stroke instead of gravity. There are two types of single acting cylinders: piston type and ram
type.
JIS symbol

Cover

Ram Tube
Clevis type cover

[Single acting ram type cylinder]

[3] Double acting cylinder

Double acting cylinder is such that hydraulic oil pressure controls the cylinder motion in both
forward and return strokes while applying a hydraulic oil pressure on both sides of the piston
alternately. There are two types of double acting cylinders: single-rod type and double-rod type.

JIS symbol

Cover Cover
Piston rod Tube Piston
(Head side) (Cap side)

[Double acting single-rod type cylinder]

− 12 −
(3) Oscillating hydraulic actuator
Oscillating hydraulic actuator is such that it uses hydraulic oil pressure to rotate its output shaft within a
predetermined range of angle.

[1] Application examples of oscillating hydraulic actuator

Valve switching Conveyor turn device Load elevating Rolling equipment Intermittent feeding
device equipment equipment

[2] Vane type oscillating hydraulic actuator

JIS symbol

There are one-vane type, two-vane type and three-vane type.

The oscillating angle ranges from 60 to 280 degrees
depending on the number of vanes. The illustration to the left
shows a two-vane 100-degree actuator. It is relatively
compact and less expensive in cost. Valve switching
mechanism is one of the typical applications.
Vane

Drain Drain

Stopper

[Double vane type]

− 13 −
(4) Hydraulic motor
A hydraulic motor is such an actuator that it uses hydraulic oil pressure to continuously rotate its output
shaft. The mechanism of hydraulic motor is similar to that of hydraulic pump but slightly different in
structure.
A hydraulic motor, featuring easy control of the revolving speed and revolution direction, is small in
size and weight but high in output power. Though variable displacement motors are available, fixed
displacement motors are frequently used in many applications and the pump flow rate control method is
commonly employed to control the revolving speed.
[1] Types

Gear motor

Hydraulic motor Vane motor

Axial type
Piston motor
Radial type

[2] Application example of hydraulic motor

Table feed, winch drive, concrete mixer, winding equipment, dividing table drive, construction
vehicle traveling

− 14 −
[3] Gear motor

JIS symbol

Out In

External drain

[Gear teeth in engagement]

Oil seal

[Gear motor]
Simple in structure and small in size and weight.
Suitable for high-speed low-torque motor.
The basic mechanism is similar to that of gear pump, but every hydraulic motor is equipped with
an external drain.
The illustration above explains that the flank area difference among the teeth on which pressure oil
is acting produces torque.

[4] Vane motor JIS symbol

The vane motor mechanism is
Rotor
similar to that of a vane pump,
but every vane has to be
projected before the motor
starts running. A vane motor,
for this purpose, uses springs or
hydraulic oil pressure.
Since a vane pump produces
torque uniformly, it is suitable
for a mid-speed mid-torque
application.

Cam ring

[Vane motor]

Vane

− 15 −
 [5] Axial piston motor

JIS symbol

Cylinder block Piston

Drain

Valve plate Slipper Cam plate

It is complicate in structure and [Axial piston motor]

expensive in cost, but high in efficiency
and significant in power output. Variable
displacement type is available as well.

[6] Radial piston motor

JIS symbol

Piston
Drain Rotary
Connecting rod valve

Rotary valve Cam

[Radial piston motor]

The hydraulic oil pressure, entering the inlet, comes into the cylinder through the rotary valve and
thrusts the pistons.
Then, the pistons thrust the eccentric cam with the connecting rods, resulting in rotation of the shaft.
While a piston travels its outward stroke, the outlet port of the rotary valve opens to send oil out.
Switching the oil inlet and outlet from one to another reverses the rotation direction.
Commonly used in low-speed high-torque applications.

− 16 −
2. Hydraulic pump
A hydraulic pump is a power source of hydraulic equipment that actuates hydraulic motors and cylinders by
providing fluid power (i.e. pressure and flow rate) to oil while receiving mechanical power produced by an
electric motor or an engine.
For hydraulic applications, positive displacement pumps are employed.
A positive displacement pump is such that it sucks and discharges oil in line with the volumetric change in the
closed oil chamber. Since its suction side and discharge side are isolated, its discharge rate remains almost
constant even when a varying load fluctuates the discharge pressure. It is, therefore, suitable for hydraulic
equipment.

(1) Types of pump

[1] Classification by discharge rate
y Fixed displacement pump: The theoretical discharge rate (cm3) per revolution is constant.
y Variable displacement pump: The theoretical discharge rate (cm3) per revolution is adjustable.

[2] Classification by structure

External gear pump

y Gear pump
Internal gear pump

Balanced vane pump

y Vane pump
Unbalance vane pump
Swash plate type
Axial piston pump
y Piston pump Bent axis type
Radial piston pump

(2) Features and descriptions of pumps

[1] Features of gear pump
y Simple in structure
y Compact in size
y Variable displacement type not available.
y Highest in suction capacity among pumps

− 17 −
 [2] External gear pump
Two gears engage with each other in the casing. As the JIS symbol
gears rotate and come out of engagement, they create
empty space, which sucks oil. The oil filling up the
space between the gears is delivered along the inner
wall of the casing toward the discharge side.
The gear teeth in engagement isolate the suction side
and discharge side from one another.

Side plate (bearing)

Driving gear

Discharge port Suction port

Driven gear

[External type]
外 接 式

[3] Internal gear pump

The principle is identical to that of the external type. On the other hand, the gears engage internally
and a crescent-shaped partition plate is provided.
Driven gear

Partition plate

Discharge port Suction port

Driving gear
[Internal type]

− 18 −
 [4] Features of vane pump
y Long life, and stable in performance for long periods
y Low in pulsation and noise
y Easy to maintain

[5] Balanced vane pump

As the rotor rotates, vanes project because of the centrifugal force and hydraulic oil pressure. They
contact and slide on the inner surface of the cam ring.
The volume of an oil chamber formed between vanes varies in line with the curve of the cam ring.
The suction port is provided in the area where the oil chamber enlarges so that oil is sucked.
The discharge port is provided in the area where the oil chamber diminishes so that oil is forcedly
discharged. With regard to the cartridge, the clamping force of the head cover fastening bolts
maintains the side clearance appropriately. Since the hydraulic oil pressure acting on the perimeter
of the rotor is in balance, it is called pressure-balanced type.
JIS symbol

Discharge port
Head cover Housing

Cam ring

Vane
Drain

Fixed side
Rotor plate

Suction port

− 19 −
 [6] Features of Piston pump
y Suitable for high pressure, and highest in pump efficiency among pumps
y Various control options can be added (Axial type). Lo (Fluid power)
Overall pump efficiency…ηp =
y Complicated in structure Ls (Shaft input power)
y Sensitive to oil contamination
Shaft input power………..Ls = P × Q
y Lowest in suction capacity
(kW) 60 × ηp

[7] Variable displacement type axial piston pump (Swash plate type)

Control cylinder
コントロールシリンダ
JIS symbol
ＪＩＳ図記号
Spool
スプール
Pressure
圧力調整ネジ adjustment screw
Drain
ドレン
Discharge rate
adjustment
吐出し量調整ネジ screw
M
０
Yoke spring
ヨークスプリング

Swash
斜 板plate
Discharge
吐出し口 port α

Suction
吸込み口 port

Slipper
スリッパ
Valve
弁 板plate
Piston
ピストン
Housing
ハウジング
Ｓ Cylinder
シリンダブロック block

The shaft and cylinder block rotate

simultaneously because they are connected
through splines. Since the top of a piston
rotates always in contact with the swash
plate through a slipper, the piston travels the Cut-off
stroke and produces pumping action
proportional to the inclination α of the
Shaft input power

swash plate while it turns. The discharge

Discharge rate

rate can be controlled with the discharge Shaft input power

rate adjustment screw.
The maximum pump pressure is set with
the pressure adjustment screw provided on
the pump. When the pump discharge
pressure comes close to the set value, the
discharge rate starts decreasing. When the Pressure Set pressure
actuator stops, the swash plate becomes (full cut-off pressure)
almost vertical and the discharge rate is
almost zero. In this manner, the discharge
pressure is maintained at the set pressure.
At the same time, the shaft input power
rapidly decreases.

− 20 −
[8] Axial piston pump (bent axis type)
Connecting rod
JIS symbol
Cylinder block

Driving flange

Discharge port
Piston

Suction port
Valve plate

Since the driving flange on the shaft end is connected with the cylinder block with pistons and ball
joints of the connecting rod, the cylinder block rotates as the shaft rotates.
The inclination α causes stroke motion of pistons. While pistons repeat the motion, oil enters the
cylinder block through the suction port of the fixed valve plate, and then, is discharged through the
discharge port.

[9] Radial piston pump (rotating cylinder/fixed valve type)

While the cylinder block rotates, the Valve stem (fixed)
piston heads run on the inner surface of
the eccentric ring and pistons repeat Cylinder block (rotary)
stroke motion. Eccentric ring
In the area where pistons travel
outward, oil enters below the piston
bottom through the hole of the valve
JIS symbol
stem. In the area where pistons travel
inward, oil is discharged through
another hole of the valve stem.

− 21 −
3. Pressure control valve
A pressure control valve is used to limit the maximum pressure of the main circuit (e.g. relief valve); reduce and
regulate pressure in certain portions of the circuit; and switch the connection of a circuit (line) when pressure in
the circuit has reached the set value.

(1) Types
y Relief valve (direct-operated type and pilot-operated type)
y Pressure reducing valve
y Sequence valve
y Counter balance valve

(2) Direct operated relief valve

A simple valve composed of a conically-shaped valve (poppet valve) and a pressure control spring.
When pressure exceeds the set value, the poppet valve opens to let pressure oil go out in a tank line.
Since the valve is prone to vibrate (chatter) in high-pressure high-flow applications, it is frequently used
as a relief valve in low-flow applications as well as a pilot valve of a pilot-operated relief valve.

Pressure control spring Poppet

JIS symbol

Pressure oil
inlet

Opening to tank line

Set pressure

Override pressure

Cracking pressure

Reseat pressure
Pressure

Flow rate

圧力−—
Pressure Flow rate characteristics
流量特性

− 22 −
(3) Pilot-operated relief valve
The advantages of a pilot-operated relief valve are as such: It is less prone to chatter because of the
pressure balancing structure of its main valve; its override pressure is small; it can be remotely
controlled using the vent port.
JIS symbol

Pressure control
spring Pilot valve
(poppet valve)

Vent port

Choke

Main spool

[1] Operation
The pilot valve, being pushed by the pressure control spring, is closed until pressure reaches the
cracking pressure. Since the choke of the main valve transmits only static pressure, no flow is
produced. There is, therefore, no differential pressure (P1 = P2), and the spring force keeps the main
valve closed.
When pressure P1 has reached the cracking pressure of the pilot valve, the pilot valve opens. Then,
pressure oil passes through the choke of the main valve and the pilot valve and comes out into a
tank line. At this time, flow rate passing through the choke produces a pressure difference (P1 − P2).
When it exceeds the spring force that keep pushing the main valve, the main valve opens. This
suppresses the increase of the primary pressure P1 and whole or part of discharge from a pump is
released into the tank line.

− 23 −
 [2] Pressure − Flow rate characteristics [3] Remote control using vent port

Remote control valve

Set pressure
設定圧力

Relief valve
Override
オーバライド圧力pressure Vent Tank
Main
主弁 valve
cracking
クラッキング圧力pressure Main valve reseat pressure
主弁レシート圧力
Pilot
パイロット弁valve

From pump
To main circuit
cracking
クラッキング圧力 pressure
Pilot valve reseat pressure
パイロット弁レシート圧力
圧力
Pressure

Flow rate
流量 Tank JIS symbol

[4] Choke
When a narrowed passage is relatively long in comparison with section size as illustrated below,
the throttle of flow is called a choke.
The choke is used to actuate a relief valve and a pressure reducing valve.

Q: Flow rate cm3/s

128Qρνl d: Hole diameter cm
P1 − P2 = P1 − P2: Differential pressure MPa
10000πd 4
ρ: Fluid density kg/cm3
ν: Coefficient of kinematic viscosity cm2/s
(1 cm2/s = 1 St = 100 cSt)
ℓ: Hole length cm

− 24 −
(4) Pressure reducing valve (pilot-operated pressure reducing valve with check valve)
A pressure reducing valve is such a pressure control valve that is used where necessary to reduce and
maintain pressure in certain portions of the circuit lower than that of the main circuit.
Operation
Switching the directional control valve to the right ( ) starts the clamping cylinder piston moving
leftward. The secondary pressure, passing through the choke of the main valve, reaches the head end of
the pilot valve. Since the pilot valve remains closed while the secondary pressure is lower than the set
value, the pressure above and below the main valve are identical because of the choke, and the spring
force maintains the main valve fully open.
When the piston reaches the forward-stroke end, the secondary pressure rises to the set pressure of the
pilot valve and the pilot valve opens, resulting in a pressure difference (P1 − P2) because of flow passing
through the choke, which overcomes the spring force and raises the main valve to close. If the primary
pressure further increases, the pressure reducing mechanism starts working in the secondary side to
maintain the secondary pressure constant at the set pressure.
The main valve opens to such an extent that it allows a limited flow amount to meet the drain amount
that enables the valve to work.
Pressure control
spring Pilot valve
Drain
(poppet valve)

Clamping cylinder

Object

Primary side
Control flow

Secondary side
Free flow

Main spool
Check valve

Choke

JIS symbol
To other circuit

− 25 −
 (5) Sequence valve with check valve
A sequence valve controls the sequential operation of a cylinder.
The sequence valve shown below is a direct-operated type that actuates the spool in rivalry with the
spring force.
When the primary pressure rises and reaches the set pressure, it actuates the spool. As a result, the port
between the primary and secondary sides is opened to traffic and pressure oil enters the secondary side.

JIS symbol

Top cover

External drain

Secondary
side
Check valve Free flow

Control flow Primary side

Spool

Minor piston
Bottom cover

− 26 −
(6) Counter balance valve (back pressure control valve)
Lifting down a heavy load requires a pressure (back pressure) produced in the outflow side of a
hydraulic cylinder in order to prevent the load from falling. A counter balance valve is used to control
the pressure in line with the amount of supply oil.

JIS symbol

Top cover

Secondary side
Free flow

Control flow Primary side

Bottom cover

− 27 −
4. Flow control valve
A flow control valve controls the flow rate in order to control the motion speed of an actuator, such as a hydraulic
cylinder and hydraulic motor.

(1) Types
There are two basic types provided below. They are available either with or without a built-in check
valve.
y Throttle valve
y Pressure compensated flow control valve

(2) One-way throttle valve

JIS symbol

Oil Hydraulic pressure

balancing hole
Piston

Inlet Free Outlet

Control flow flow

Spool

Relief valve

The structure is simple. The flow rate slightly varies as the load pressure changes.
It is not possible to totally shut the flow down to zero.

− 28 −
(3) Pressure compensated flow control valve (with check valve)
A mechanism to compensate a constant pressure difference between before and after the throttle is
additionally built in the valve so that the through flow rate remains constant even when load pressure
varies.

JIS symbol

Pressure
compensated spool Valve inlet
Check valve Pressure
compensated orifice
Free flow

Relief valve

Valve outlet
Control flow

Flow control
Throttle A spool

[1] Operation
Pressure P1 right before the throttle A acts on areas A2 and A3 of the pressure compensated spool.
Acting on area A1 are outlet pressure P2 and spring force F.
Pressure P1 is maintained in such a manner that a force acting on area A1 of the pressure
compensated spool and another on area A2 + A3 are balanced (the pressure compensated orifice
reduces inlet pressure P0).
F + P2 × A1 = P1 × (A2 + A3) → Where A1 = A2 + A3:
F + P2 × A1 = P1 × A1 → F = A1 (P1 − P2)

F
A1
= P1 − P2

As explained above, the pressure compensated spool operates accordingly so that the pressure
F
difference P1 − P2 over the throttle A is equal to A , the hydraulic equivalent of spring force.
1

− 29 −
[2] Orifice
When a narrowed passage is relatively short in comparison with section size as illustrated below,
the throttle is called an orifice. The orifice is used as a flow rate controlling throttle.

Orifice

2(P1 − P2 )
Q = 100CA
ρ

Q: Flow rate cm3/s

C: Flow rate coefficient
A: Orifice cross section cm2
ρ: Fluid density kg/cm3
P1 − P2: Pressure difference between before and after orifice MPa

− 30 −
5. Directional control valve
A directional control valve conducts open/close operation and blocks a back flow in an oil line. It is used to
control the oil flow for the purpose of starting/stopping an actuator, converting a motion direction, and such.

(1) Types
y Check valve
y Pilot-operated check valve
y Directional control valve Manually-operated valve

Cam-operated valve

Solenoid-operated valve

Pilot-operated directional control valve

Solenoid-controlled pilot-operated directional control valve

(2) Check valve

A check valve allows a free flow of fluid in only one direction and blocks a flow in the opposite
direction. There are two types available: in-line check valves and angle check valves.
Selection of a spring used in a check valve depends upon an application. A back-flow check application
(simply as a check valve) requires a spring with a force equivalent to more or less the cracking pressure
0.05 MPa. A spring of more or less 0.45 MPa is used in a back-pressure valve (resistance valve)
application.

JIS symbol

(with spring)
(a) In-line check valve (b) Angle check valve

Free flow Free flow

− 31 −
(3) Pilot-operated check valve
A pilot-operated check valve is used to keep a cylinder load in a position for a long period of time.
The operation of a pilot-operated check valve is such that it takes in the pump discharge pressure as a
pilot pressure as needed by switching a directional control valve to [ ] side so that the pilot spool,
being pushed on its bottom, rises to forcibly open the check valve in order to allow a free back flow.
The space above the pilot spool is furnished with a drain hole so that it is kept not enclosed.

JIS symbol

Check valve

Free flow
Free back flow

Drain

Pilot pressure

Pilot spool

in order that the pilot pressure is

released in a tank line while the check
valve is in the neutral position, [ ] is
commonly used in design of check valve
neutral position.

− 32 −
 (4) Directional control valve
[1] Outline of functions of directional control valve
Number of ports, number of positions, spool type, return type, spool operation type and such, as
provided in following items (A) to (E), have to be indicated in order to specify the functions of a
directional control valve.
(A) Number of ports: Number of line ports to be provided to a directional control valve.
A 4-port type (having ports P, R, A and B) is most frequently used.
(B) Number of positions:

2-position
Only two positions − actuator “forward” and “backward”
valve

3-position
Actuator “neutral stop position” is included as well.
valve

(C) Spool type: It specifies the connecting status among ports when a 3-position valve is in neutral
position.

Spool types Symbols Spool structures Descriptions

Valve in neutral position, with all the

All port block ports and the oil lines closed and shut
off respectively

Contrary to all port block, all the ports

are connected, and both the pressure
All port open
oil supply side and the load side
communicate with a tank.

Pressure port block Only port P is closed, while ports A

(ABR connection) and B are connected with port R.

Center bypass Ports P and R are connected, while

(PR connection) ports A and B are closed.

− 33 −
 (D) Return type (how the operated spool returns)
Names Symbols Function descriptions
Applicable to 3-position valve. Upon receipt of an
external signal, the position shifts to either the left or
Spring center
the right. It automatically returns to the neutral when
the signal is off.

Applicable to 2-position valve. The position remains

unchanged when the signal is off.
No spring
NOTE: There is such a manually-operated valve that
has three positions and detent mechanism.

Applicable to 2-position valve. Upon receipt of an

external signal, the position shifts from the normal to
Spring offset
another. It automatically returns to the original when
the signal is off.

(E) Spool operation type

Manually-operated A valve operated by hand

A valve operated by a mechanism, such as a cam, a roller,

Mechanically-operated
etc.
Operation method

Pilot-operated A valve operated by pilot hydraulic pressure

Solenoid-controlled A valve operated by electromagnetic force

A valve (operated by electromagnetic force) that actuates

Solenoid-controlled
the main spool valve using hydraulic pressure from a pilot
pilot-operated
valve

[2] Solenoid-operated valve

Since a solenoid-operated valve is operated using electric signals, automatic operation, remote
control, emergency shutoff and such are easily realized. The solenoid includes a cartridge filled
with oil. A moving core in the oil moves and switches the spool when externally excited.

− 34 −
 Spring center type
JIS symbol

Terminal box

Solenoid a Solenoid b

Moving core
Nut

Manual pin

Body Spool Coil Cartridge

Push pin

JIS symbol
No spring type

Terminal box

Solenoid a Solenoid b

JIS symbol
Spring offset type

Terminal box

Solenoid b

Return spring

− 35 −
[3] Solenoid-controlled pilot-operated directional control valve
The flow rate that a solenoid-controlled valve is capable of handling is limited because of
electromagnetic force, hydrodynamic shock, durability and such. A solenoid-controlled
pilot-operated directional control valve is used in a high-flow application or for the purpose of
ensuring shockless effect in switching operation. Though the indication of spool type is same with
that of solenoid-controlled valve, there is a regulation in combining a pilot valve
(solenoid-controlled valve) and a main valve.

Pilot valve

Solenoid a Solenoid b

Inner pilot

Main centering
spring

Main spool

Main directional
control valve body
External drain

JIS symbols
(detailed)

JIS symbols
(simplified)

− 36 −
 Chapter 3

Hydraulic fluid
 Hydraulic Fluid

The role of hydraulic fluid is very important in energy transfer. There are various types of hydraulic fluids in use
depending on the machine type and operation requirements. The knowledge of hydraulic fluid, as with hydraulic
equipment, is essential in design, manufacturing, operation and control of hydraulic systems.

1. Hydraulic fluid types

General hydraulic …… Turbine oil-based fluid with rust and oxidation
fluid (R&O) prevention agents added (frequently called R&O,
short for “rust and oxidation”).

Mineral fluids Anti-wearing …… Fluid made of R&O and additional Anti-wearing

hydraulic fluid agents (e.g. zinc), mostly used where pressure
exceeds 14 MPa.

High viscosity index …… Fluid with viscosity index improver added, used
hydraulic fluid in an application that needs to diminish
temperature-viscosity changes.

Phosphate hydraulic …… Fluid with lubricity equivalent to mineral fluids,

fluid excellent in fire resistance. You need to pay
attention to paint and sealing material before use
Hydraulic fluid Synthetic fluids (nitrile-butadiene rubber not applicable).

Polyol ester (fatty …… Fluid with fire resistance less than phosphate
acid) hydraulic fluid hydraulic fluids, but tolerates epoxy resin paint
and nitrile-butadiene rubber sealing material.

Water + glycolic …… Etylene glycol + water (37 to 40%)

hydraulic fluid

Aqueous fluids Water-in-oil type …… Water: 40% approx. Water particles

hydraulic fluid (W/O Oil
emulsions)

Oil-in-water type …… Water: 90 to 95%

hydraulic fluid (O/W
Water
emulsions)
Oil particles

− 37 −
2. Viscosity of hydraulic fluid
Kinematic viscosity is used to express the viscosity of hydraulic fluid.
Using a capillary viscometer, kinematic viscosity is found by measuring the efflux time of a specified amount of
oil in a capillary tube under forces of gravity.
The unit of kinematic viscosity is “mm2/s = cSt (centistoke)”. Kinematic viscosity of a hydraulic fluid is expressed
using a kinematic viscosity (mm2/s) when the fluid temperature is 40°C.

3. Viscosity index (VI)

In the case of oil, the higher its temperature, the lower the viscosity, and the lower its temperature, the higher the
viscosity. VI is used to express such viscosity − temperature characteristics.
Oil with a high VI value produces relatively less viscosity changes due to temperature changes.
(The VI values of petroleum hydraulic fluids refined from high-VI paraffin-base crude range between 100 and 115
in general except for special types.)

4. Appropriate working range of hydraulic fluid

Hydraulic equipment is designed to properly work when the hydraulic fluid viscosity is appropriate.

Too low viscosity increased leak lowered efficiency of pumps and motors
shortage of oil film progress of wearing Lock-up

Too high viscosity diminished fluidity increase line pressure loss

Increased power loss
Impaired responsiveness
Pump suction failure

The desirable working temperature, therefore, ranges from 15 to 55°C.

(Using oil at a temperature over 60°C accelerates oil deterioration.)
Water + glycolic hydraulic fluids prefer temperatures between 15 and 50°C.

− 38 −
 Viscosity − Temperature Chart

Viscosity − Temperature Chart

Kinematic viscosity

Temperature °C

Example:
40°C············ 32 mm2/s at 15°C mm2/s
100°C·········· 5.8 mm2/s at 60°C mm2/s

40°C············ 68 mm2/s at 30°C mm2/s

100°C·········· 8.7 mm2/s at 50°C mm2/s

− 39 −
5. Compressibility
In line with the development in utilization of high pressure, compressibility of hydraulic fluid has become
recognized these days.
Compressibility β is expressed as follows.

3
1 ⋅ ∆V (cm )
β=
V 3 ∆P (MPa )
(cm )

To find the reduced volume by

compression, use an equivalent to V: volume before compression
the above equation. ∆V: volume reduced by compression pressure ∆P
∆V = β·V·∆P

Types of hydraulic fluid Β (1/MPa)

Mineral hydraulic fluid 6 × 10−4

Phosphate hydraulic fluid 3.3 × 10−4
Water + glycolic hydraulic fluid 2.87 × 10−4

6. Aeration and influence

Air mixed in a hydraulic fluid destabilizes piston motions of a hydraulic cylinder and may cause breathing. The
more air is mixed, the more frequently fluid produces cavities in it when passing through the low pressure areas
before and after a pump and valve, which is called cavitation. Cavitation causes decline in the volumetric
efficiency, noise and erosion.

7. Water incorporation and influence

Water mixed in a hydraulic fluid causes deterioration in the lubricity of the fluid, malfunction of hydraulic
equipment and wearing as well as reducing rust resistance and accelerating oxidization of the fluid resulting in
rusty metal and shortened life respectively.

− 40 −
8. Hydraulic fluid contamination and its effects
A hydraulic fluid includes various types of and plenty of foreign particles that have entered through many routes
of entry. The contaminant particles not only accelerate wearing of bearing and sliding surfaces but also lead to
hydraulic equipment failures.
There are two methods for measuring contaminant particles: counting method and weighing method. The counting
method has been frequently used.

9. Hydraulic fluid and Fire Defense Law

A hydraulic fluid with flashing point is designated as a hazardous material under the Fire Defense Law. Aqueous
fluids do not have flashing point in normal condition and are not designated so. On the contrary, Mineral and
synthetic fluids have flashing point of mostly 200°C or higher and are designated as 4th Group, 4th Class
Petroleum, which will be subject to regulation when 6,000 liters or over are stored. (in Japanese law)

* Small-scaled hazardous materials

Even when the quantity of stored fluid is less than 6,000 liters, a quantity not less than 1/5 of stored fluid (i.e.
1,200 liters or over) shall be subject to the fire prevention ordinance of a local authority and designated as
Small-scaled hazardous materials.

4th-Group hazardous materials: Types and specified quantities

Hazardous
Classifications Flashing points States Typical products
quantities (L)
Water-insoluble
200 Gasoline, acetone
1st class fluid
Under 21°C
Petroleum Water-soluble
400
fluid
4th Group Alcohol 400 Ethyl and methyl alcohol
Water-insoluble
1000 Kerosene, light oil
2nd class Not less than 21°C and fluid
Petroleum not more than 70°C Water-soluble
2000
fluid
Water-insoluble Heavy oil (some hydraulic fluids
2000
(inflammable 3rd class Not less than 70°C and fluid fall into this category)
fluid) Petroleum not more than 200°C Water-soluble
4000
fluid
4th class Gear oil, cylinder oil, general
200°C and over 6000
Petroleum hydraulic fluid
Animal and plant
10000
oil
Notes (1) Water-insoluble fluid means any fluid other than water-soluble fluid.
(2) Water-soluble fluid is such that when it is mixed with a same quantity of purified water by being
stirred gently at 20°C under 1 atmospheric pressure, the mixed solution presents and maintains
homogeneous appearance even after the mixing flow has stopped.

* Things to do in conformance with the Fire Defense Law

Application for construction permit, oil tank leak test by filling water, complete examination, use of
explosion-proof electric devices, etc.

− 41 −
 Chapter 4

Basic Circuit
1. Unload circuit
In a circuit using a fixed displacement pump, all the discharge from a pump returns into a tank through a relief
valve when a cylinder stops.
Pressure rises to open the relief valve, and the fluid power, turning into heat without working, is lost.
What is useful to reduce the power loss is a system that applies low pressure to release the pump discharge into a
tank.

(1) Circuit using center bypass valve

To be used where one single hydraulic drive is involved.

(2) Vent unload circuit

Relief valve

Vent line
To main circuit

From pump

Tank

Since the flow rate in a vent line is small, a small size solenoid-controlled valve can be used for control
regardless of the pump capacity.

− 42 −
2. Circuit to control pressure required for hydraulic drive
(1) Circuit for switching P-line pressure
Set pressure

Remote control valve

Set pressure

Relief valve

Vent Tank
Directional control valve
for pressure control

To main circuit
Set pressure

From pump
P-line

Fluid tank

It is used where the hydraulic cylinder output has to be controlled in line with load changes.
The diagram provided above shows a 3-step pressure-switching circuit. In the circuit, with the main
relief valve set at the highest pressure P1 and two pilot relief valves set at mid pressure P2 and low
pressure P3 respectively, P-line pressure can be switched over using a small size solenoid-controlled
valve for vent-line control.
(The above method controls pressure across the entire circuit. It is, therefore, not applicable where a
circuit includes multiple driving units and a reduced pressure works against one or more of the driving
units.)

(2) Circuit for controlling pressure by series

It is used where more than one series system is involved and pressure of one or more of the series
systems have to be controlled below the set pressure of a relief valve.
Where a line (A or B) of a directional control valve is used to reduce pressure in only one side of a
cylinder, a pressure reducing valve with check valve has to be installed in the line.

− 43 −
3. Control method of flow control valve
There are two methods for controlling the actuator speed: a method that changes the discharge rate using a
variable displacement pump, and another that uses a combination of a metering pump and a flow control valve.
There are three methods to control a flow control valve: meter-out, meter-in and bleed-off methods.

(1) Meter-out method

Head side
Cap side

P1 × A × 102 + W
P2 =
B × 102

This method controls the inflow from a pump by throttling down the outflow from an actuator and
releases excess flow into a fluid tank through a relief valve.
This is applicable when load is either positive or negative. The pressure P2 right before the throttle (i.e.
head side of stroke in the above diagram) varies depending on the direction and size of load.
With such load direction as shown in the diagram, in particular, P2 exceeds the set pressure of the relief
valve. If P2 goes beyond the allowable pressure of the actuator, it can not be used without treatment. It is
necessary to keep P2 pressure down by reducing cap-side pressure (with an additional relief valve or
pressure reducing valve).

− 44 −
(2) Meter-in method

Load pressure

Relief pressure

This method throttles down the inflow of an actuator and releases excess flow into a fluid tank through a
relief valve.
It is applicable when load is positive.
Since the actuator is liable to work self-assertively when load is negative, a counterbalance valve has to
be added and used together with the meter-in control method.

(3) Bleed-off method

Load pressure

This method bypasses part of inflow to an actuator into a fluid tank.

This is better for efficiency since pump pressure variation corresponding to load changes is always
below the set pressure of a relief valve unlike the meter-in and meter-out methods.
This is applicable where just one hydraulic drive unit is involved.
On the other hand, this is not applicable where precise speed control is required since pump discharge
rate varies somewhat when load pressure fluctuates widely or fluid temperature changes.

− 45 −
4. Circuit for controlling high load
High load operation requires use of high pressure and high flow. Abruptly switching such fluid produces surge
pressure. Following methods are employed to mitigate the problem.

(1) Circuit using solenoid-controlled pilot-operated directional control valve

In the circuit with a solenoid-controlled pilot-operated directional control valve, the shock produced in
switching is mitigated by controlling the taper notch effect and switching time using a metering valve.

Solenoid a Solenoid b

Metering valve

Main valve

Taper notch

− 46 −
 (2) 2-speed control circuit
This method conducts a 2-speed control by alternately
switching two circuits by a solenoid-controlled valve,
small- and large-capacity circuits including a flow
control valve respectively, arranged in parallel.

Small-capacity
circuit
Large-capacity
circuit

One forward stroke

One-stroke time

In starting a cylinder, the small-capacity circuit feeds fluid so that the cylinder piston begins traveling
slowly. When the piston has traveled a certain distance, the large-capacity circuit starts feeding to
increase the speed.
In stopping a cylinder, the large-capacity circuit stops feeding to decelerate the speed, and then, the
small-capacity circuit stops feeding to stop the cylinder. (A sequence control is used to control the
On/Off sequence and timing of each solenoid for start/stop operation.)

(3) Decompression circuit

When a cylinder piston is at the end of down
stroke and pressure in press process reaches
the upper limit “Hi” (value set in a pressure
switch), a signal is sent out. Upon receipt of Pressure-releasing valve
the signal, the main directional control valve
returns to the neutral position and a
pressure-releasing valve opens to slowly
release pressure.

When pressure comes down to the lower

limit “Lo” (value set in a pressure switch), a
signal is sent out. The signal allows the main
directional control valve to shift the position
for lifting operation.

− 47 −
5. Accelerating circuit (to produce a speed faster than that available by
pump discharge rate)
(1) Differential circuit
This is applicable where high cylinder output is not needed and the cylinder piston needs to travel fast in
its forward stroke.
The piston travels forward at an accelerated speed when the directional control valve is in the left
position and returns when the valve is in the right position.

A1 … Cylinder cap-side cross-sectional area (cm2)

A2 … Cylinder head-side cross-sectional area (cm2)
a … Piston rod cross-sectional area (cm2)
υ … Piston speed (cm/s)
QP … Pump discharge rate (cm3/s)
QR … Outflow (cm3/s)
Q … Confluent flow rate (cm3/s)
F … Output (N)
P1 … Pressure acting on A1 (cap-side) (MPa)
P2 … Pressure acting on A2 (head-side) (MPa)

Q = QP + QR
A1 × υ = QP + A2 × υ
QP = A1 × υ − A2 × υ
QP = (A1 − A2) × υ (Output)
F = P1 × A1 × 102 − P2 × A2 × 102
QP QP
∴υ = =
A1 − A 2 a

− 48 −
(2) Accelerating circuit using auxiliary cylinder

Upper fluid Pressure-releasing

Fluid tank-side tank
valve

Prefill valve

Main cylinder

Auxiliary cylinder
Pilot
port Press plate

[Prefill valve]

This circuit is frequently used where a large-diameter cylinder is employed for a hydraulic press.
To increase working efficiency, processes other than press process employ rapid-run. Using a
small-diameter auxiliary cylinder for this purpose enables rapid-run with a small pump.

[Downward stroke] Pump discharge drives the auxiliary cylinder piston downward while the main
cylinder indraws fluid by itself from the upper fluid tank. When pressure starts
rising and reaches the set pressure of the sequence valve after the press plate
contacts a workpiece, the valve opens and pump discharge enters the main
cylinder so that pump discharge pressure is used for pressing. After pressing is
complete, the pressure releasing valve opens to slowly release pressure.

[Upward stroke] While pressure lifts up the auxiliary cylinder piston, part of the pressure
opens the upper prefill valve in order to send fluid from the main cylinder
back to the upper fluid tank.

− 49 −
6. Circuit for sequential operation of cylinder
This circuit operates more than one cylinder in accordance with the specified sequence.
There are two methods to implement the sequence: one by cylinder pressure detection (using a sequence valve)
and another by cylinder position detection.
Using limit switches to detect positions is common.

(1) Circuit using sequence valve

Secondary

Primary

[Sequence valve]

This circuit, capable of controlling up to two or three cylinders, is used in a line of manually-operated
valve.

− 50 −
 (2) Circuit using limit switch and solenoid-controlled valve

The circuit turns solenoid of a solenoid-controlled valve on and off while detecting the position of a
cylinder piston with limit switches.
It is capable of handling complicated motions and wide-ranging control.

7. Circuit to maintain back pressure (negative load)

Secondary

Primary

[Counterbalance valve]

The circuit employs a counterbalance valve to maintain back pressure that is produced by load W.

− 51 −
8. Position-keeping circuit

Check valve

Free flow
Free back flow

Drain

Pilot pressure

Pilot spool

[Pilot-operated check valve]

The circuit employs a pilot-operated check valve in it
to hold a cylinder piston in any position with reliability.

9. Brake circuit

While a relief valve absorbs inertial force, a lower check valve secures supply so that pressure of the opposite line
is not negative.

− 52 −
10. Closed circuit
High pressure safety valve
Flushing valve
Charge relief valve A

Charge relief valve B

Charge pump

In a closed circuit, a pump produces a pressure and flow rate only in line with a load. No other circuits can
compete with closed circuit in efficiency.
Alternating the pump discharge direction switches the motor rotation between forward and reverse, and changing
the pump discharge rate controls the number of revolutions of a motor.
In order to prevent negative pressure in the low pressure line when a leak takes place in the high pressure line (on
the pump discharge side), a charge pump is employed to supply pressure into the low pressure line. The relief
valve B determines the pressure.
Pressure of the high pressure line opens the flushing valve and pressure runs from the low pressure line to the
charge relief valve B. At that time, the charge relief valve has to remain closed, and for this purpose, the pressure
of A is higher than that of B.
Fluid discharged from the charge relief valve B returns into the fluid tank after cooling and lubricating the motor
and pump. Then, the fluid enters the low pressure line after being filtered with a filter. This chain flow forms the
flushing circuit.
When the motor stops, the flushing valve shifts to the neutral position. At the same time, the charge relief valve B
closes and the charge relief valve A opens.
(The filter of the charge pump is installed on the discharge side in some cases.)

− 53 −
11. Filter circuit for hydraulic fluid
The most essential practice in using hydraulic equipment is to maintain hydraulic fluid cleanliness.
Utilization of high pressure is more common today. The higher the pressure, the smaller the clearance in pumps
and valves, resulting in increased problems caused by contaminations in fluid.
Filter circuit weight has been increasing so as to prevent troubles of and extend the life of hydraulic equipment.

(1) Circuit in return side

The most simple circuit, frequently used in small-size equipment.
Large-size equipment needs a large flow rate in the return line, resulting in a large-capacity filter.

(2) Circuit in discharge side

It is employed in a circuit that uses valves (e.g. servo valve) that require a high fluid cleanliness.
A high-pressure filter meeting the pump capacity is used.

(3) Circuit dedicated to filtering purpose

The circuit uses a small-size pump and filter, but is capable of filtering fluid in a large-capacity tank. It
is used in large-size equipment.

Circuit dedicated to filtering

purpose
Discharge-side filter

Return-side filter

(1) Circuit in return side (2) Circuit in discharge side (3) Circuit dedicated to filtering
purpose

− 54 −
TEXT No. YU-A1-01
2004. 9 DB