L-6 Hydraulic Circuit Design & Analysis

Hydraulic Circuit Design & Analysis
By G/micael G/mariam
Learning objectives:
 Upon completing this chapter, you should be able to:
 Describe the operation of complete hydraulic circuits
drawn using graphic symbols.
 Determine the operating speeds and load carrying
capacities of regenerative cylinders.
 Analyze hydraulic circuits to evaluate the safety of
operation.
 Design hydraulic circuits to perform a desired function.
 Perform and analysis hydraulic circuit operation,
including the effects of frictional losses.
 Analyze the speed control of hydraulic cylinders.
Introduction:
 A hydraulic circuit is a group of components such
as pumps, actuators, control valves, and
conductors arranged so that they will perform a
useful task.
 Hydraulic circuits are developed using graphic
symbols for all components.
Design Considerations
Safety of Operation
􀂅 Pressure and Temperature ratings
􀂅 Interlocks for sequential operations
􀂅 Emergency shutdown features
􀂅 Power failure locks
􀂅 Operation speed
􀂅 Environment conditions
Meet functional requirements

􀂅 Life expectancy same as machine
􀂅 Facilitate good maintenance practice
􀂅 Compatibility with electrical and mechanical components
􀂅 Withstand operational hazards
Efficiency of Operation
􀂅 Keep system Simple, Safe and Functional
􀂅 Access to parts need repair or adjustment
􀂅 Design to keep minimum operational cost
􀂅 Design to prevent and remove contamination.
Linear Circuits
Simple reciprocating circuit
Reservoir
• Strainer
• Pump
• Flexible
coupling
• Electric Motor
• Connectors
• Relief valve
• DCV – 4 way
• Hyd. Cylinder
Circuit Design Approach
 What are the specifications of the job?
􀂅 Force requirement – e.g. 8 KN
􀂅 Length of work stroke – e.g. 15 cm
􀂅 Speed of piston and rod assembly –e.g. 0.5 sec
What Size of Cylinder is needed?
􀂅 Force known. Cylinder Area & Operating
Pressure must be selected. F = PA
􀂅 Standard bore and rod size cylinders
 Cylinder Selection Reasoning
Large Diameter Cylinder
a. Operates at Low Pressure
b. Requires Bigger pump for speed
Small Diameter Cylinder
a. Operates at High Pressure
b. Smaller pump give speed
Cylinder selected = e.g.50 mm bore
Find Pressure and then select suitable pump
 What Capacity Pump is needed?
􀂅 Max Cylinder Speed required
􀂅 Flow rate = (Cyl Area)x(Stroke)/(time)
􀂅 Pump selection
 What size of Electric Motor needed?
􀂅 Calculate power required to run Pump
􀂅 Consider efficiency of pump
􀂅 Shaft size, type and electric source
What Size reservoir should be used?
􀂅 2.5-3.0 times the pump capacity
Size of pump inlet?
􀂅 Inlet flow velocity = 60-150 cm/sec
Size of Discharge tubing?
􀂅 Outlet flow velocity = 200 – 450 cm/sec
Relief valve selection
􀂅 Pressure range
􀂅 Valve port size
Direction Control valve
􀂅 Based on function
Control of a Single Acting
Hydraulic Cylinder
 Three Way Two Position Manually
Actuated Spring Offset DCV
Control of a Double Acting Hydraulic Cylinder
 Four Way Three Position
Manually Actuated Spring
Centered DCV
Regenerative Circuit
 Pressurized fluid discharge
returned to system
 Speed up extending speed
 Retraction bypass DCV
Cylinder extension speed
QT = QP +QR
QP = QT - QR
QP = APvpext – (AP - Ar)vpext
vpext = QP/ Ar
is:
and retraction Speed
.vpret = QP/( AP - Ar)
Ratio of extending and retracting
Speed :
 vpext/ vpret = (QP/ Ar)/( QP/( AP - Ar))
= ( AP - Ar)/Ar
vpext/ vpret = (AP/ Ar) – 1
 Load carrying capacity
during extension;
Fload ext = P Ar Partial circuit showing flow paths
during cylinder extension stroke
Drilling Machine Application
Spring centered position –
Rapid spindle advance
Left envelope –
Slow feed
Right envelope –
Retracts piston
PUMP Unloading circuit
Unloading valve
 unloads the pump at
the ends of extending
and retracting strokes
As well as in spring
centered position of
DCV
Double Pump Hydraulic System
 Punch Press
 Initial Low Pressure high
flow rate requirement.
 When punching operation
begins, increased pressure Low pressure line Relief valve
opens unloading valve to
unload low pressure
pump. High pressure line
Unloadingvalve
Unloading
valve
Counterbalance Valve
􀂅 To keep vertically
mounted cylinder in upward
position while pump is
idling.
􀂅 Counterbalance valve is
set to open at slightly above
the pressure required to hold
the piston up.
Hydraulic Cylinder Sequence Circuit
􀂅 Left Envelop: Left Cyl
extends completely and then
Right Cyl extend.
􀂅 Right Envelop: Right
Cyl retracts fully and then
Left Cyl retracts.
work piece
Automatic Cylinder Reciprocating System
􀂅 Two sequence valve
sensing strokes
completion by
corresponding pressure
build up.
􀂅 Each check valve and
corresponding pilot line
prevents shifting of the
four way valve until the
particular stroke has
been completed.
Locked Cylinder Using Pilot Check Valves
􀂅 Lock Cylinder
so that piston can
not move by
external load.
􀂅 What happens if
regular check
valves are used
instead of the pilot
operated check
valves??
Cylinder Synchronizing Circuit
􀂅 Two identical Cylinders connected in parallel

􀂅 Loads identical – Moves in exact synchronization
􀂅 But Loads Not exactly Identical (practical situation) and
􀂅 Cylinders also not exactly identical (packing Friction)
􀂅 Cylinders connected in Series

􀂅 For two cylinder to be synchronized
Piston Area of Cyl 2 = Piston Area of Cyl 1- Rod area of Cyl1
 Pump pressure should overcome loads acting on both cylinders.

P1 Ap1- P2(Ap1-Ar1) = F1
P2 Ap2- P3(Ap2-Ar2) = F2 and P3= 0 due to the drain line to the tank
P1 Ap1 = F1+F2
Fail Safe Circuit
􀂅 Designed to prevent
injury to operator or damage
to equipment.
􀂅 Prevent Cylinder from
accidentally falling on an
Operator in the event of:
􀂅 Hydraulic line ruptures
􀂅 Person inadvertently
operates manual override on
Pilot actuated DCV when
pump not operating
Speed control of a hydraulic cylinder
 Meter in speed control of hydraulic cylinder

 Speed control during cylinder extension stroke using flow control valve .
 DCV actuated- cylinder extend and the extending speed depends on the setting of
FCV. Maximum cylinder speed during FCV fully open.
 DCV deactuated(spring offset mode)-cylinder retracts as oil flows from the cylinder
to the oil tank through the check valve and FCV.
Speed Control of a Hydraulic Motor
􀂅 Hydraulic Motor – Rotary
Motion
􀂅 Spring Center Position
Motor hydraulically locked
􀂅 Left Envelop
Rotates Clockwise
􀂅 Right Envelop
Rotates Anticlockwise
Hydraulic Motor Braking System
􀂅 Hydraulic motor may be driving
Machine having a large inertia.
􀂅 Creates Flywheel effect.
􀂅 Stopping motor, acts as a pump.
􀂅 Circuit is designed to provide
fluid to the motor while it is
pumping.
􀂅 Provisions should be made for
discharge fluid from motor to be
returned to Tank.
􀂅 This would stop motor without
damaging.
Example
 A double acting cylinder is hooked up in the regenerative circuit. the
relief valve setting is 105bars. The piston area is 130cm2 and rod area is
65cm2. if the pump flow is 0.006m3/, find the cylinder speed and load-
carrying capacity for
a. Extending stroke
b. Retracting stroke
c. The power delivered to the load assuming the load equals the cylinder
load-carrying capacity.
Example
Q1. For the double pump system above what be the pressure settings of the
unloading valve and pressure relief valve under the following conditions?
a. Sheet metal punching operation requires a force of 8000N.
b. Hydraulic cylinder has a 3.75cm diameter piston and a 1.25cm diameter
rod.
c. During rapid extension of the cylinder, a frictional pressure loss of
675kpa occurs in the line from the high flow pump to the blank end of
the cylinder. During the same time, a 350kpa pressure loss occurs in the
return line from the rod end of the cylinder to the oil tank. frictional
pressure losses in these lines are negligible small during the punching
operation.
d. Assuming that the unloading valve and relief valve pressure setting (for
their full pump flow requirements) should be 50% higher than the
pressure required to overcome frictional pressure losses and the cylinder
punching load, respectively.
Q2. For the Cylinder Synchronizing Circuit in
series, what pump pressure is required if the
cylinder loads are 22kN each and cylinder 1 has a
piston area of 65 cm2?
Q3. repeat Q2 for the retraction strokes of the
cylinders (loads pull to right). The piston and rod
areas of cylinder2 equal 50cm2 and 15cm2,
respectively.

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Hydraulic Circuit Design & Analysis

Meet functional requirements

􀂅 Two identical Cylinders connected in parallel

􀂅 Cylinders connected in Series

 Pump pressure should overcome loads acting on both cylinders.

 Meter in speed control of hydraulic cylinder

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