Rexroth Formulas

Sales Industry Sector Metallurgy
Formulary Hydraulics
Hydraulic Formulary
Author: Houman Hatami

Tel.: +49-9352-18-1225
Fax: +49-9352-18-1293
houman.hatami@boschrexroth.de
10.01.2013
CONTENTS
RELATIONS BETWEEN UNITS ............................................................................................................. 4
IMPORTANT CHARACTERISTIC VALUES OF HYDRAULIC FLUIDS ................................................ 6
GENERAL HYDRAULIC RELATIONS ................................................................................................... 7
PISTON PRESSURE FORCE ...................................................................................................................... 7
PISTON FORCES ..................................................................................................................................... 7
HYDRAULIC PRESS ................................................................................................................................. 7
CONTINUITY EQUATION ........................................................................................................................... 8
PISTION SPEED....................................................................................................................................... 8
PRESSURE INTENSIFIER .......................................................................................................................... 8
HYDRAULIC SYSTEM COMPONENT ................................................................................................... 9
HYDRO PUMP ......................................................................................................................................... 9
HYDRO MOTOR ....................................................................................................................................... 9
Hydro motor variable ...................................................................................................................... 10
Hydro motor fixed ........................................................................................................................... 11
Hydro motor intrinsic frequency ..................................................................................................... 12
HYDRO PISTON ..................................................................................................................................... 13
Differential piston ............................................................................................................................ 14
Double acting cylinder .................................................................................................................... 15
Cylinder in differential control ......................................................................................................... 16
Cylinder intrinsic frequency at differential cylinder ......................................................................... 17
Cylinder intrinsic frequency at double acting cylinder .................................................................... 18
Cylinder intrinsic frequency at plunger cylinder.............................................................................. 19
PIPING................................................................................................................................................... 20
APPLICATION EXAMPLES FOR SPECIFICATION OF THE CYLINDER PRESSURES AND
VOLUME FLOWS UNDER POSITIVE AND NEGATIVE LOADS ........................................................ 21
DIFFERENTIAL CYLINDER EXTENDING WITH POSITIVE LOAD ..................................................................... 22
DIFFERENTIAL CYLINDER RETRACTING WITH POSITIVE LOAD ................................................................... 23
DIFFERENTIAL CYLINDER EXTENDING WITH NETAGIVE LOAD.................................................................... 24
DIFFERENTIAL CYLINDER RETRACTING WITH NEGATIVE LOAD .................................................................. 25
DIFFERENTIAL CYLINDER EXTENDING AT AN INCLINED PLANE WITH POSITIVE LOAD .................................. 26
DIFFERENTIAL CYLINDER RETRACTING AT AN INCLINED PLANE WITH POSITIVE LOAD................................. 27
DIFFERENTIAL CYLINDER EXTENDING AT AN INCLINED PLANE WITH NEGATIVE LOAD ................................ 28
DIFFERENTIAL CYLINDER RETRACTING AT AN LINCLINED PBLANE WITH NEGATIVE LOAD ............................ 29
HYDRAULIC MOTOR WITH POSITIVE LOAD ............................................................................................... 30
HYDRAULIC MOTOR WITH NEGATIVE LOAD.............................................................................................. 31
IDENTIFICATION OF THE REDUCED MASSES OF DIFFERENT SYSTEMS ................................... 32
LINEARE DRIVES .................................................................................................................................. 33
Primary applications (Energy method) ........................................................................................... 33
Concentrated mass at linear movements....................................................................................... 35
Distributed mass at linear movements ........................................................................................... 36
ROTATION ............................................................................................................................................ 37
COMBINATION OF LINEAR AND ROTATIONAL MOVEMENT .......................................................................... 38
HYDRAULIC RESISTANCES...39
ORIFICE EQUATION ............................................................................................................................... 39
TROTTLE EQUATION .............................................................................................................................. 39
10.01.2013
HYDRO ACCUMULATOR .................................................................................................................... 40

HEAT EXCHANGER (OIL- WATER) .................................................................................................... 41
LAYOUT OF A VALVE ......................................................................................................................... 43
10.01.2013
Relation between Units

Size
Lengths
Surfaces
Volume
Density
Unit
Symbol
Relation
Micrometer
1m = 0,001mm
Millimeter
mm
1mm = 0,1cm = 0,01dm = 0,001m
Centimeter
cm
1cm = 10mm = 10.000m
Decimeter
dm
1dm = 10cm = 100mm = 100.000m
Meter
1m = 10dm = 100cm = 1.000mm = 1.000.000m
Kilometer
km
1km = 1.000m = 100.000cm = 1.000.000mm
Square centimeter
cm2
1cm2 = 100mm2
Square decimeter
dm2
1dm2 = 100cm2 = 10.000mm2
Square meter
m2
1m2 = 100dm2 = 10.000cm2 = 1.000.000mm2
Are
1a = 100m2
Hectare
ha
1ha = 100a = 10.000m2
Square kilometer
km2
1km2 = 100ha = 10.000a = 1.000.000m2
Cubic centimeter
cm3
1cm3 = 1.000mm3 = 1ml = 0,001l
Cubic decimeter
dm3
1dm3 = 1.000cm3 = 1.000.000mm3
Cubic meter
m3
1m3 = 1.000dm3 = 1.000.000cm3
Milliliter
ml
1ml = 0,001l = 1cm3
Liter
1l = 1.000 ml = 1dm3
Hectoliter
hl
1hl = 100l = 100dm3
Gram/
g
cm3
g
kg
t
g
=1 3 =1 3 =1
cm3
dm
m
ml
Cubic centimeter
Force
Newton
1N = 1
Weight
kg m
J
=1
s2
m
1daN = 10N
Torque
Newton meter
Nm
1Nm = 1J
Pressure
Pascal
Pa
Bar
Bar
1Pa = 1N/m2 = 0,01mbar = 1kg

m s2
psi =
pound
inch 2
1bar = 10
Psi
1psi = 0,06895 bar
kp
cm 2
10.01.2013
N
N
= 100.000 2 = 10 5 Pa
2
cm
m
kp
= 0,981bar
cm 2
Mass
Acceleration
Milligram
mg
1mg = 0,001g
Gram
1g = 1.000mg
Kilogram
kg
1kg = 1000g = 1.000.000 mg
Ton
1t = 1000kg = 1.000.000g
Mega gram
Mg
1Mg = 1t
Meter/
m
s2
per square second
Angular speed
One/ Second
Radiant/ Second
Power
m
N
=1
s2
kg
1g = 9,81 m/s2
= 2n
1
s
n in 1/s
rad
s
Nm
J
kg m m
=1 =1 2
s
s
s
s
Watt
Newton meter/ second
Nm/s
Joule/ second
J/s
Work/ Energy
Watt second
Ws
Heat volume
Newton meter
Nm
Joule
Kilowatt hour
kWh
1kWh = 1.000 Wh = 10003600Ws = 3,6106Ws
Kilo joule
kJ
= 3,6103kJ = 3600kJ = 3,6MJ
Mega joule
MJ
Mechanic
Newton/ square
N
mm2
tension
millimeter
Plane angle
Second
1 = 1/60
Minute
1 = 60
Degree
Radiant
rad
1 = 60 = 3600 = rad
180
1W = 1
1Ws = 1Nm = 1
kg m
m = 1J
s2
N
= 10bar = 1MPa
mm2
1rad = 1m/m = 57,2957

1rad = 180/
Speed
One/second
1/s
One/minute
1/min
1 1
= s = 60 min 1
s
1
1
= min 1 =
60s
min
10.01.2013
Important Characteristic Values of Hydraulic Fluids
HLP
HFC
HFA
(3%)
HFD
880
1085
1000
925
10-100
36-50
0,7
15-70
12000-14000
20400-23800
1500017500
1800021000
[Bar]
Specific Heat at 20C
2,1
3,3
4,2
1,3-1,5
[kJ/kgK]
Thermal Conductivity at 20C
0,14
0,4
0,6
0,11
[W/mK]
Optimal Temperatures
40-50
35-50
35-50
35-50
[C]
Water Content
40-50
80-97
[%]
Cavitation Tendency
low
high
very high
low
Density at 20C
3
[kg/m ]
Kinematic Viscosity
at 40C
2
[mm /s]
Compressions Module E
at 50C
10.01.2013
General Hydraulic Relations

Piston Pressure Force
Figure
Equation / Equation Variations
Symbols / Units
F = 10 p A
F = p A 10
A=
d=
F = piston pressure force[N]
d2
4
p = fluid pressure[bar]
A = piston surface[cm2]
d = piston diameter[cm]
= efficiency cylinder
4 F 0,1
p
p = 0,1
4 F
d2
Piston Forces
Figure
Symbols / Units
F = pe A 10
F = pe A 10
A=
F = piston pressure force[N]

pe = excess pressure on the piston[bar]
d2
4
A = effective piston surface[cm2]

d = piston diameter[cm]
= efficiency cylinder
A For annulus surface:
A=
(D2 d 2 )
4
Hydraulic Press
Figure
Symbols / Units
F1 = Force at the pump piston[N]
F1
F
= 2
A1 A 2
F2 = Force at the operating piston[N]

A1 = Surface of the pump piston [cm2]
F1 s1 = F2 s2
A2 = Surface of the operating piston [cm2]

s1 = Stroke of the pump piston [cm]
s2 = Stroke of the operating piston [cm]
10.01.2013
F1 A1 s 2
=
=
F2 A2 s1
= Gear ratio
Continuity Equation
Figure
Q1 = Q 2
Symbols / Units
Q1,2 = Volume flows [cm3/s, dm3/s, m3/s]
Q1 = A 1 v 1
A1,2 = Area surfaces [cm2, dm2, m2]

v1,2 = Velocities
Q2 = A 2 v2
[cm/s, dm/s, m/s]
A 1 v1 = A 2 v 2
Piston Speed
Figure
v1 =
Q1
A1
v1,2 = Piston speed [cm/s]

Q1,2 = Volume flow [cm3/s]
Q
v2 = 2
A2
A1 =
Symbols / Units
A1 = Effective piston surface (circle) [cm2]

A2 = Effective piston surface (ring) [cm2]
d2
4
(D2 d 2 )
A2 =
4
Pressure Intensifier
Figure
Symbols / Units
p1 = Pressure in the small cylinder [bar]
p1 A 1 = p 2 A 2
A1 = Piston surface [cm2]

p2 = Pressure at the large cylinder [bar]
A2 = Piston surface [cm2]
10.01.2013
Hydraulic System Components

Hydro Pump
Q=
V n vol
1000
pQ
Pan =
600 ges
Q = Volume flow [l/min]

[l/min]
V = Nominal volume [cm3]

n = Drive speed of the pump [min-1]
[kW]
Pan = Drive power [kW]

p = Service pressure [bar]
1,59 V p
[Nm]
M=
100 mh
M = Drive torque [Nm]

ges = Total efficiency (0,8-0,85)
ges = vol mh
vol = Volumetric efficiency (0,9-0,95)

mh = Hydro-mechanic efficiency(0,9-0,95)
Hydro Motor
Q = Volume flow [l/min]

V = Nominal volume [cm3]
Q=
V n
1000 vol
n = Drive speed of the pump [min-1]

ges = Total efficiency (0,8-0,85)
vol = Volumetric efficiency (0,9-0,95)
Q vol 1000
n=
V
M ab
mh = Hydro-mechanic efficiency
(0,9-0,95)
p V mh
=
= 1,59 V p mh 10 2
20
Pab =
p = Pressure difference between motor inlet and
outlet (bar)
p Q ges
10.01.2013
Pab = Output power of the motor [kW]

Mab = Output torque [Nm]
600
Hydro Motor Variable
Md =
P=
n=
Md = Torque [Nm]
n = Speed [min-1]
Md n
30000
30000
Md =
n=
30000 P
Md
M d max
i Getr
i = Gear ratio
Getr = Gear efficiency
mh = Mech./hydraulic efficiency
vol = Vol. efficiency
Vg = Flow volume [cm3]
Md
Vg mh
Vg n
1000 vol
QP =
P=
Mdmax = Max torque [Nm]
n max
i
p = 20
Q=
P = Power [kW]
Vg n vol
1000
Q p
600 ges
10.01.2013
10
Hydro Motor Fixed
Md =
P=
n=
Md = Torque [Nm]
n = Speed [min-1]
Md n
30000
30000
Md =
n=
30000 P
Md
M d max
i Getr
i = Gear ratio
Getr = Gear efficiency
mh = Mech./hydraulic efficiency
vol = Vol. efficiency
Vg = Flow volume [cm3]
Md
Vg mh
Vg n
1000 vol
QP =
P=
Mdmax = Max torque [Nm]
n max
i
p = 20
Q=
P = Power [kW]
Vg n vol
1000
Q p
600 ges
10.01.2013
11
Hydro Motor Intrinsic Frequency
V
( G )2
2 E
2
0 =
VG
J red
+ VR )
(
2
f0 = 0
2
10.01.2013
VG = Displacement [cm3]
0 = Intrinsic angular frequency [1/s]
f0 = Intrinsic frequency [Hz]

Jred = Moment of inertia red. [kgm2]
El = 1400 N/mm2
VR = Volume of the line [cm3]
12
Hydro Cylinder
d d 1 0,785 2
[cm ]
A= 1
=
400
100
2
d1 = Piston diameter [mm]
d2 = Piston rod diameter [mm]

p = Service pressure [bar]
d 2 0,785 2
[cm ]
100
2
A st =
v = Stroke speed [m/s]

V = Stroke volume [l]
(d d 2 ) 0,785 2
[cm ]
AR = 1
100
2
Q = Volume flow, considering the leakages

(l/min)
p d1 0,785
[kN]
FD =
10000
Qth = Volume flow, without considering the
p (d 1 d 2 ) 0,785
[kN]
Fz =
10000
vol = Volumetric efficiency (approx. 0,95)
h
Q
[m/s]
v=
=
t 1000 A 6
t = Stroke time [s]
Qth = 6 A v =
Q=
V=
t=
leakages (l/min)
V
60
t
h = Stroke [mm]
FD
[l/min]
FZ
Q th
vol.
FS
Ah
[l]
10000
A h6
Q 1000
10.01.2013
[s]
13
Differential Cylinder
dK = Piston diameter [mm]
4 FD
pK
d K = 100
dst = Rod diameter [mm]

FD = Pressure force [kN]
pK =
4 10 FD
d K2
p St =
4 104 FZ
(d K 2 d St 2 )
Fz = Traction force [kN]

pK = Pressure at the piston side [bar]
= Aspect ratio
QK = Volume flow piston side [l/min]

QSt = Volume flow rod side [l/min]
va = Extending speed [m/s]
dK
2
2
(d K d St )
ve = Retracting speed [m/s]

Volp = Working volume [l]
6
2
va d K
QK =
400
QSt =
ve =
va =
VolF = Fill-up volume [l]

h = Stroke [mm]
6
2
2
v e (d K d St )
400
QSt
6
2
2
(d K d St )
400
QK
6
2
dK
400
Vol p =
Vol F =
4 10
d St h
h (d K d St )
4 10
10.01.2013
14
Double Acting Cylinder
pA =
pB =
QA =
4 104
4 104
FA
2
2
(d K d StA )
dstA = Rod diameter A-side [mm]

dstB = Rod diameter B-side [mm]
FB
2
2
(d K d StB )
FA = Force A [kN]
FB = Force B [kN]
6
2
2
v a (d K d StA )
400
pA = Pressure at the A-side [bar]

pB = Pressure at the B-side [bar]
QA = Volume flow A-side [l/min]
6
2
2
QB =
v b (d K d StB )
400
ve =
va =
QB = Volume flow B-side [l/min]

va = Speed a [m/s]
QSt
vb = Speed b [m/s]
6
2
2
(d K d St )
400
Volp = Compensating volume [l]

VolFA = Fill-up volume A [l]
QK
VolFB = Fill-up volume B [l]
6
2
dK
400
Vol p =
4 10
Vol FA =
Vol FB =
d St h
2
h (d K d StA )
h (d K d StB )
4 10
4 10
10.01.2013
15
Cylinder in Differential Control
4 FD
d st = 100
p St
dst = Rod diameter [mm]

FD = Pressure force [kN]
4 10 FD
d St 2
4
pK =
Fz = Traction force [kN]

pK = Pressure at the piston side [bar]
pSt = Pressure at the rod side [bar]
4 104 FZ
p St =
(d K 2 d St 2 )
Q=
h = Stroke [mm]
QK = Volume flow piston side [l/min]
6
2
v a d St
400
QSt = Volume flow rod side [l/min]
Extension:
va =
QP = Pump flow [l/min]

va = Extending speed [m/s]
QP
6
2
d St
400
Q d
QK = P 2 K
d St
ve = Retracting speed [m/s]

Volp = Working volume [l]
VolF = Fill-up volume [l]
Q P (d K d St )
2
d St
2
QSt =
Retraction:
ve =
QP
6
2
2
(d K d St )
400
QSt=QP
QP d K
QK =
2
2
(d K d St )
2
Vol p =
Vol F =
4 10
d St h
h (d K d St )
4 10
10.01.2013
16
Cylinder Intrinsic Frequency at Differential Cylinders
AK = Piston surface [cm2]
d
AK = K
4
100
2
AR = Piston ring surface [cm2]

dSt = Piston rod diameter [mm]
(d d St )
AR = K
4
100
2
dRK = NW- piston side [mm]

LK = Length of piston side [mm]
dRSt = NW-rod side [mm]
d L
= RK K
4
1000
2
VRK
LSt = Length of rod side [mm]

h = Stroke [cm]
d L
= RSt St
4
1000
VRK = Volume of the line piston side [cm3]
VRSt
mRK =
VRSt = Volume of the line rod side [cm3]

mRK = Mass of the oil in the line piston side [kg]
VRK l
1000
mRSt = Mass of the oil in the line rod side [kg]

hK = Position at min intrinsic frequency [cm]
V l
= RSt
1000
mRSt
f0 = Intrinsic frequency [Hz]
A h V
V
R
+ RSt RK
3
3
A3
AR
AK
R
hk =
1
1
(
)
+
AR
AK
01 = 0
f 01 =
A EL
AR El
1
( K
+
)
A
h
A
(
h hK )
m
K
R
K
+ VRK
+ VRSt
10
10
2
0 =
f0 =
0 = Angular frequency
0
2
4
mlred
1
d
= mRK K + mRSt
d RK
d RSt
10.01.2013
400 A R
17
01
2
mred
mlred + mred
Cylinder Intrinsic Frequency at Double Acting Cylinders
AR = Piston ring surface [cm2]
(d d St )
AR = K
4
100
2

dSt = Piston rod diameter [mm]
dR = NW [mm]
d L
VR = RK K
4
1000
LK = Length of the piston side [mm]
V l
mR = R
1000
h = Stroke [mm]
mR = Mass of the oil in the line [kg]

f0 = Intrinsic frequency
2 E l
AR
0 = 100
(
)
AR h
m red
+ VRSt
10
2
Equation applies only to the middle position of the

double rod cylinder
Natural frequency of any position can be calculated
using the equation for the differential cylinder (as shown
on page 17, however AK = AR)
f0 =
0
2
mlred
1
= 2 mRK
dR
01 = 0
f 01 =
400 A R
mred
mlred + mred
01
2
10.01.2013
18
Cylinder Intrinsic Frequency for Plunger Cylinders
AK = Piston surface [cm2]
d
AK = K
4
100
2

dR = Diameter of the piping [mm]
LK = Length piston side [mm]
d L
VR = K K
4
1000
2
LR = Length of the line [mm]

h = Stroke [mm]
V l
mR = R
1000

MR = Mass of the oil in the line [kg]
2
E
AK
0 = 100 l (
)
mred AK h + VRSt
f0 =
0
2
m lred
d
= 2 mR K
dR
01 = 0
f 01 =
f0 = Intrinsic frequency
mred
mlred + mred
01
2
10.01.2013
19
Piping
p =
l v 2 10
d2
lam.
turb.
0,316
= 4
Re
vd
turb. = Pipe friction coefficient for turbulent flow
l = Length of the line [m]

v = Velocity in the line [m/s]
103
6 d2
d =
lam. = Pipe friction coefficient for laminar flow
v=
= Density [kg/dm ] (0,89)

= Pipe friction coefficient
64
=
Re
Re =
p = Pressure loss at direct piping [bar]
102
d = Internal diameter of the piping [mm]

= Kinematic viscosity [mm /s]
2
Q = Volume flow in the piping [l/min]
400 Q
6 v
10.01.2013
20
Application Examples for Specification of the Cylinder Pressures

and Volume Flows under Positive and Negative Load
Nomenclature
Parameters
Symbols
Units
Acceleration / deceleration
m/s2
Cylinder surface
A1
cm2
Ring surface
A2
cm2
Aspect ratio
=A1/A2
FT
daN
Fa=0,1ma
daN
External forces
FE
daN
Friction forces (coulomb friction)
FC
daN
Sealing friction force
FR
daN
Weight force
daN
Total force
Acceleration force
Mass
G
+ mK
g
kg
Piston mass
mK
kg
Volume flow
Q=0,06 Avmax
l/min
vmax
cm/s
T=J+ TL
Nm
m=
Torque
Load torque
TL
Nm
Angular acceleration
rad/s2
Inertia moment
kgm2
10.01.2013
21
Differential Cylinder Extending with Positive Load
Calculation:
Layout:
FT = Fa+FR+FC+FE
p1 =
[daN]
Given Parameters
p 2 = 5,25 +
FT = 4450 daN
PS = 210 bar
PT = 5,25 bar
A1 = 53,50 cm2
A2 = 38,10 cm2
= 1,40
vmax = 30,00 cm/s
==> p1 und p2
Q N = 96
p S A2 + R [ FT + ( pT A2 )]
bar
A2 (1 + 3 )
p p
p2 = pT + S 2 1 bar
Verification of the cylinder dimensioning and

calculation of the nominal volume flow QN,
depending on the load pressure p1.
Q= 0,06A1vmax
QN = Q
l/min
35
p S p1
l/min
Selection of a Servo valve 10% larger than the

calculated nominal volume flow.
10.01.2013
210 120
= 52bar
1,4 2
Q= 0,0653,530=96 l/min
p1 =
210 38,1 + 1,4 2 [4450 + (5,25 38,1)]

= 120bar
38,1(1 + 1,4 3 )
22
35
= 60l / min
210 120
Differential Cylinder Retracting with Positive Load
Layout:
Calculation:
FT = Fa+FR+FC+FE
[daN]
p2 =
Given Parameters
p 1 = 5,25 + [(210 187)1,4 2 ] = 52bar
FT = 4450 daN
PS = 210 bar
PT = 5,25 bar
A1 = 53,50 cm2
A2 = 38,10 cm2
= 1,40
vmax = 30,00 cm/s
==> p1 und p2
Q= 0,0638,130=69 l/min
( p A 3 ) + FT + ( pT A2 )]
bar
p2 = S 2
A2 (1 + 3 )
Q N = 96
p1 = pT + [( p S p2 ) 2 ] bar
Q= 0,06A2vmax
l/min
35
pS p 2
l/min
QN = Q

10.01.2013
(210 38,1 1,42 ) + 4450 + (5,25 38,1 1,4)]

= 187bar
38,1(1 + 1,43 )
23
35
= 84l / min
210 187
Differential Cylinder Extending with Negative Load
Calculation:
Layout:
FT = Fa+FR-G
p1 =
[daN]
Given Parameters
p2 = 0 +
FT = -2225 daN
PS = 175 bar
PT = 0 bar
2
A1 = 81,3 cm
2
A2 = 61,3 cm
= 1,3
vmax = 12,7 cm/s
==> p1 und p2
p S A2 + 2 [ FT + ( pT A2 )]
bar
A2 (1 + 3 )
p p
p2 = pT + S 2 1 bar
Q N = 62

Q= 0,06A1vmax
l/min
35
p S p1
l/min

10.01.2013
175 36
= 82bar
1,32
Q= 0,0681,312,7=62 l/min
p1 =
QN = Q
175 61,3 + 1,32 [2225 + (0 61,3)]

= 36bar
61,3(1 + 1,33 )
24
35
= 31l / min
175 36
Differential Cylinder Retracting with Negative Load
Calculation:
Layout:
FT = Fa+FR-G
p2 =
[daN]
(210 61,3 + 1,32 ) 4450 + (0 61,3 1,3)]

= 122bar
61,3(1 + 1,33 )
Given Parameters
p 1 = 0 + [(210 122)] = 149 bar
FT = -4450 daN
PS = 210 bar
PT = 0 bar
2
A1 = 81,3 cm
2
A2 = 61,3 cm
= 1,3
vmax = 25,4 cm/s
==> p1 und p2
Q= 0,0661,325,4=93 l/min
p2 =
Q N = 93
( p S A2 ) + FT + ( pT A2 )]
bar
A2 (1 + 3 )
3
p1 = pT + [( p S p2 ) 2 ] bar
Q= 0,06A2vmax
l/min
35
pS p 2
l/min
QN = Q

10.01.2013
25
35
= 59l / min
210 122
Differential Cylinder Retracting at an Inclined Plane with Positive Load
Calculation:
Layout:
(140 19,9) + 1,62 [2225 + (3,5 19,9)]

= 85bar
19,9(1 + 1,63 )
FT = Fa+FE+FS+[G(cos+sin)] daN
p1 =
Given Parameters
p 2 = 35 +
FT = 2225 daN
PS = 140 bar
PT = 3,5 bar
2
A1 = 31,6 cm
2
A2 = 19,9 cm
= 1,6
vmax = 12,7 cm/s
==> p1 and p2
p1 =
Q= 0,0631,612,7=24 l/min
Q N = 24
p S A2 + 2 [ F + ( pT A2 )]
p2 = pT +
A2 (1 + 3 )
p S p1
bar
bar

Q= 0,06A1vmax
l/min
35
p S p1
l/min
QN = Q

10.01.2013
140 85
= 25bar
1,6 2
26
35
= 19 l/min
140 85
Differential Cylinder Retracting at an Inclined Plane with Positive Load
Calculation:
Layout:
(140 19,9 1,63 ) + 1780 + [3,5 19,9 1,6)]

= 131bar
19,9(1 + 1,63 )
FT =Fa+FE+FS+[G(cos+sin)] daN
p2 =
Given Parameters
p 1 = 3,5 + [(140 131) 1,6 2 = 26bar
FT = 1780 daN
PS = 140 bar
PT = 3,5 bar
2
A1 = 31,6 cm
2
A2 = 19,9 cm
= 1,6
vmax = 12,7 cm/s
==> p1 and p2
p2 =
Q= 0,0619,912,7=15 l/min
Q N = 15
( p S A2 3 ) + F + ( pT A2 )]
A2 (1 + 3 )
bar
p1 = pT + [( p S p2 ) 2 ] bar
Q= 0,06A2vmax
QN = Q
l/min
35
pS p 2
l/min

10.01.2013
27
35
= 30 l/min
140 131
Differential Cylinder Extending at an Inclined Plane with Negative Load
Calculation:
Layout:
FT = Fa+FE+FR+[G(cos-sin)] daN
p1 =
(210 106) + 1,22 [6675 + (0 106)]

= 131bar
106(1 + 1,43 )
Given Parameters
FT = -6675 daN
PS = 210 bar
PT = 0 bar
2
A1 = 53,5 cm
2
A2 = 38,1 cm
= 1,4
vmax = 25,4 cm/s
==> p1 und p2
p1 =
Caution!!!
Negative load is leading to cylinder cavitation.

Specified parameters to be changed by means of
using a larger cylinder size, increasing the system
pressure or reducing the necessary total force.
A1 = 126 cm
p S A2 + 2 [ F + ( pT A2 )]
p2 = pT +
A2 (1 + 3 )
p S p1
bar
bar

Q= 0,06A1vmax
QN = Q
p2 =
l/min

10.01.2013
A2 = 106 cm
210 44
= 116bar
1,2 2
Q= 0,0612625,4=192 l/min
35
Q N = 192
= 88 l/min
210 44
l/min
35
p S p1
28
R=1,2
Differential Cylinder Retracting at an Inclined Plane with Negative Load
Calculation:
Layout:
(210 38,1 1,43 ) + [ 6675 + (0 38,1 1,4)]

= 107 bar
38,1(1 + 1,43 )
F = Fa+FE+FR+[G(cos-sin)] daN
p2 =
Given Parameters
p 1 = 0 + [(210 107) 1,4 2 ] = 202 bar
F = -6675 daN
PS = 210 bar
PT = 0 bar
2
A1 = 53,5 cm
2
A2 = 38,1 cm
= 1,4
vmax = 25,4 cm/s
==> p1 and p2
Q= 0,0638,125,4=58 l/min
Q N = 58
( p S A2 3 ) + F + ( pT A2 )]
bar
p2 =
A2 (1 + 3 )
p1 = pT + [( p S p2 ) 2 ] bar

Q= 0,06A2vmax
QN = Q
l/min
35
pS p 2
l/min

10.01.2013
29
35
= 34 l/min
210 107
Hydraulic Motor with a Positive Load
Calculation:
Layout:
T = J+TL
p1 =
[Nm]
p 2 = 210 127 + 0 = 83bar
Given Parameters
T = 56,5 Nm
PS = 210 bar
PT = 0 bar
3
DM = 82 cm /rad
M = 10 rad/s
QM= 0,011082=8,2 l/min
Q N = 8,2
==> p1 and p2
p S + p T 10T
bar
+
2
DM
p 2 = p S p1 + p T bar
p1 =

QM= 0,01MDM
QN = QM
l/min
35
p S p1
l/min

10.01.2013
210 + 0 10 56,5
+
= 127bar
2
82
30
35
= 5,3 l/min
210 127
Hydraulic Motor with a Negative Load
Calculation:
Layout:
T = J-TL
p1 =
[Nm]
p 2 = 210 40 + 0 = 170bar
Given Parameters
T = -170 Nm
PS = 210 bar
PT = 0 bar
3
DM = 82 cm /rad
M = 10 rad/s
QM= 0,011082=8,2 l/min
Q N = 8,2
==> p1 and p2
p S + p T 10T
bar
+
2
DM
p 2 = p S p1 + p T bar
p1 =

QM= 0,01MDM
QN = QM
l/min
35
p S p1
l/min

10.01.2013
210 + 0 10 ( 170)
+
= 40bar
2
82
31
35
= 3,6 l/min
210 40
Identification of the Reduced Masses of Different Systems

The different components (cylinder / motors ) have to be dimensioned for the layout of the
necessary forces of a hydraulic system, so that the acceleration and the deceleration of a mass is
correct and targeted.
The mechanics of the system are defining the stroke of the cylinders and motors.
Speed- and force calculations have to be carried out.
Statements with view to acceleration and its effects on the system can be made by fixing the reduced
mass of a system.
The reduced mass (M) is a concentrated mass, exerting the same force and acceleration
components as the regular mass at the correct system.
The reduced moment of inertia (Ie) has to be considered for rotational systems.
The reduced mass has to be fixed in a first step for considerations with stroke measuring systems or
for applications with deceleration of a mass!
Newtons second axiom is used for the specification of the acceleration forces.
F = m a
F= force [N]
m= mass [kg]
a= acceleration [m/s2]
The following equation is applied for rotational movements:
= I
= torque [Nm]
= moment of inertia [kgm2]
= angular acceleration [rad/s2]
10.01.2013
32
Linear Drives
Primary Applications (Energy Method)
The mass is a concentrated mass and the rod l is weightless. The cylinder axis is positioned
rectangular to the rod l.
Relation between cylinder and rod:
vc v m
=
r
l
ac am
=
r
l
Needed torque for acceleration of the mass:
= IX = F r
= m l 2 X
= m l2 X
I = m l2
am
l
am
l
= m lXa m
==>
F=
m l am
= m i am
r
i=
l
r
mi can be considered as mass movement m.
F = m i am = m i
l ac
= m i2 a c = M a c
r
mit
ac am
=
r
l
F= cylinder force
M= reduced mass
ac= acceleration of the cylinder rod
General validity:
M = mi
The same result can be obtained by the aid of the energy method (kinetic energy of the mass m). The
dependence of the mass movement with the cylinder movement can be specified with the help of the
geometry of the system.
2
Energy of the mass:
1
1
KE = I 2 = m l 2 2
2
2
10.01.2013
(I=mi2)
33
1
v
= m l2 c
r
2
=
=
(vc=r )
1
l2
2
m 2 vc
2
r
1
2
M vc
2
10.01.2013
M=mi
34
and i=l/r
Concentrated Mass with Linear Movements
v is the horizontal component of v. v is positioned rectangular to rod l.

Energy method:
1
1
KE = I 2 = m l 2 2
2
2
v
1
= m l2
2
r
( =v/r)
l2
1
2
= m 2 v
r
2
1
2
= m i2 v
2
with v=vcos
==> KE =
1
m i2 v 2
2
1 m i2
1
v2 = M v2
2
2 (cos )
2
with M = m
If:
i2
==> M is position-depending
(cos ) 2
= 0 then, =1
and M=mi2
=90 then, cos=0
and M=
=30 then, cos=0,866
and M = m
i2
0,75
If a cylinder is moving a mass, as shown in the preceding figure, and the movement is situated between -30 and
+30, the acceleration- and deceleration forces have to be calculated in the center of motion with a reduced mass,
twice as large as the one in the neutral center.
10.01.2013
35
Distributed Mass at Linear Movements
When considering the same rod l with the mass m, you can here also calculate the reduced mass of
the rod.
1
1
1
KE = I 2 = X m l 2 2
2
2
3
v
1
1
= X m l2
2
3
r
1
m l2
3
( =v/r)
l2
1
1
2
= X m 2 v
r
2
3
1
1
2
= X m i2 v
2
3
with v=vcos
M=
1
1 m i2
1
X
v2 = M v2
2
2
3 (cos a )
3
1 m i2
2 (cos a ) 2
10.01.2013
36
Rotation
If considering now a rotating mass with a moment of inertia I, driven by a motor (ratio D/d).
1
1
d
KE = I 2 m = I ( ) 2
2
2
D
I= moment of inertia [kgm2]
1 d
= I 2
2 D
= angular acceleration [rad/s2]
1
= I i2 2
2
1
= Ie 2
2
Ie= Ii2
i=d/D
If a gearbox has to be used, i has to be considered.

2
If i=D/d, then Ie=I/i
10.01.2013
37
Combination of Linear and Rotational Movement
A mass m is here moved by a wheel with radius r. The wheel is weightless.
KE =
=
1
2
m ( r )
2
=
1
m v2
2
v=r
1
m r 2 2
2
1
Ie 2
2
10.01.2013
Ie= mr
38
Hydraulic Resistances
The resistance of an area reduction is the change of the applied pressure difference
corresponding volume flow change.
R=
p to the
d (p)
dQ
Orifice Equation
QBlende = 0,6 K
dB
2 p
4
2
K = flow coefficient (0,6-0,8)

= 0,88 [kg/dm3]
dB = orifice diameter [mm]
p = pressure difference [bar]

Qorifice= [l/min]
Throttle Equation
Q Drossel
r4
( p1 p 2 )
=
8 l
Qthrottle= [m3/s]
= dynamic viscosity [kg/ms]
l = throttle length [m]

r = radius [m]
= kinematic viscosity [m2/s]
= 880 [kg/m3]
10.01.2013
39
Hydro Accumulator
1
1
p 0 p1
V = V0 1
p1 p 2
p2 =
V0 =
p1
V
1
1
p0
V0
p
V
1
1
p 0 p1
1
p2
p1
10.01.2013
= 1,4 (adiabatic compression)

V = effective volume [l]
V0 = accumulator size [l]

p0 = gas filling pressure [bar]
p1 = service pressure min [bar] (pressure loss at the
valve)
p2 = service pressure max [bar]
p0 = <0,9*P1
Provide an accumulator in the pressure circuit for
pressure-controlled pumps!
Swivel time of pump tSA of the pump catalog.
V = Q t SA
40
Heat Exchanger (Oil - Water)

ETD = t l t K
Vl = oil flow [l/min]

PV = dissipation power [kW]
P
p 01 = V
ETD
tl = inlet temperature oil [C]
14 PV
t K =
VK
tK = inlet temperature cooling water [C]
tl = cooling of the oil [K]

tK = heating of the cooling water [K]
VK = cooling water flow [l/min]

Calculation of tl is different, depending on the
ETD = inlet temperature difference [K]
respective hydraulic fluid.
p01 = spec. cooling capacity [kW/h]
HFA
t l =
HLP/HFD
14,7 PV
Vl
t l =
HFC
36 PV
Vl
t l =
17,2 PV
Vl
The size of the heat exchangers can be defined by the calculated value p01 of the diagrams of the
different manufacturers.
10.01.2013
41
Example AB-Standards:
10.01.2013
42
Layout of a Valve
The necessary volume flow can be calculated

based on the cylinder data as well as on the
extending and retracting speeds.
Q= 0,06A2vmax
l/min
X
pS p2
l/min
QN = Q
P= PS system pr.-PLload pr.-P Treturn pressure
(Load pressure
2
*System pressure)
3
X= 35 (Servo valve) pressure loss via a leading edge

X= 35 (Prop valve) pressure loss via a leading edge
(Prop valve with shell)
At optimal efficiency
FT = load force [daN]
PS = system pressure [bar]
PT = return pressure [bar]
A1 = piston surface cm2
A2 = ring surface cm2
= aspect ratio cylinder
vmax = extending speed of the cylinder cm/s
X= 5 (Prop valve) pressure loss via a leading edge

(Prop valve without shell)
Selection of a valve 10% larger than the

calculated nominal volume flow
p1 and p2
p2 =
( p S A2 3 ) + FT + ( pT A2 )]
bar
A2 (1 + 3 )
p1 = pT + [( p S p2 ) 2 ] bar

Translation: Harm/March 16, 2011

10.01.2013
43

Rexroth Formulas

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Sales Industry Sector Metallurgy

Author: Houman Hatami

Sales Industry Sector Metallurgy

Sales Industry Sector Metallurgy

HYDRO ACCUMULATOR .................................................................................................................... 40

Sales Industry Sector Metallurgy

Relation between Units

1mm = 0,1cm = 0,01dm = 0,001m

1cm = 10mm = 10.000m

1dm = 10cm = 100mm = 100.000m

1m = 10dm = 100cm = 1.000mm = 1.000.000m

1km = 1.000m = 100.000cm = 1.000.000mm

1dm2 = 100cm2 = 10.000mm2

1m2 = 100dm2 = 10.000cm2 = 1.000.000mm2

1ha = 100a = 10.000m2

1km2 = 100ha = 10.000a = 1.000.000m2

1cm3 = 1.000mm3 = 1ml = 0,001l

1dm3 = 1.000cm3 = 1.000.000mm3

1m3 = 1.000dm3 = 1.000.000cm3

1ml = 0,001l = 1cm3

1hl = 100l = 100dm3

1Pa = 1N/m2 = 0,01mbar = 1kg

1psi = 0,06895 bar

Sales Industry Sector Metallurgy

1kg = 1000g = 1.000.000 mg

per square second

Newton meter/ second

1kWh = 1.000 Wh = 10003600Ws = 3,6106Ws

= 3,6103kJ = 3600kJ = 3,6MJ

1rad = 1m/m = 57,2957

Sales Industry Sector Metallurgy

Important Characteristic Values of Hydraulic Fluids

Sales Industry Sector Metallurgy

General Hydraulic Relations

Equation / Equation Variations

F = piston pressure force[N]

Equation / Equation Variations

F = piston pressure force[N]

A = effective piston surface[cm2]

A For annulus surface:

Equation / Equation Variations

F2 = Force at the operating piston[N]

A2 = Surface of the operating piston [cm2]

Sales Industry Sector Metallurgy

Equation / Equation Variations

Q1,2 = Volume flows [cm3/s, dm3/s, m3/s]

A1,2 = Area surfaces [cm2, dm2, m2]

[cm/s, dm/s, m/s]

Equation / Equation Variations

v1,2 = Piston speed [cm/s]

A1 = Effective piston surface (circle) [cm2]

Equation / Equation Variations

p1 = Pressure in the small cylinder [bar]

A1 = Piston surface [cm2]

Sales Industry Sector Metallurgy

Hydraulic System Components

Q = Volume flow [l/min]

V = Nominal volume [cm3]

Pan = Drive power [kW]

M = Drive torque [Nm]

vol = Volumetric efficiency (0,9-0,95)

Q = Volume flow [l/min]

n = Drive speed of the pump [min-1]

p = Pressure difference between motor inlet and