Hydraulic Circuit

Design & Analysis

Dr. Sunil Jha

MEL334: Low Cost Automation

Design Considerations

Safety of Operation
Pressure

and Temperature ratings

Interlocks for sequential operations
Emergency shutdown features
Power failure locks
Operation speed
Environment conditions

MEL334: Low Cost Automation

Design Considerations

Meet functional requirements

Meet

required performance specification

Life expectancy same as machine
Facilitate good maintenance practice
Compatibility with electrical and mechanical
components
Withstand operational hazards

MEL334: Low Cost Automation

Design Considerations

Efficiency of Operation
Keep

system Simple, Safe and Functional

Access to parts need repair or adjustment
Design to keep min operational cost
Design to prevent and remove contamination.

MEL334: Low Cost Automation

Linear Circuits

Simple reciprocating circuit

Reservoir
Strainer
Pump
Flexible coupling
Electric Motor
Connectors
Relief valve
DCV 4 way
Hyd. Cylinder

MEL334: Low Cost Automation

Circuit Design Approach

What are the specifications of the job?

Force

requirement 8 kN
Length of work stroke 15 cm
Speed of piston and rod assembly 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
MEL334: Low Cost Automation

Circuit Design Approach

Cylinder Selection Reasoning

Large

Diameter Cylinder
Operates at Low Pressure
Requires Bigger pump for speed
Small Diameter Cylinder
Operates at High Pressure
Smaller pump give speed

Cylinder selected = 50 mm bore

Find Pressure and then select suitable pump
MEL334: Low Cost Automation

Circuit Design Approach

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
MEL334: Low Cost Automation

Circuit Design Approach

What Size reservoir should be used?

2.5-3.0

times the pump capacity

What size of Electric Motor needed?

Calculate

power required to run Pump

Consider efficiency of pump
Shaft size, type and electric source

MEL334: Low Cost Automation

Circuit Design Approach

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
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Control of a Single Acting Hydraulic

Cylinder
Two Position
Three Way
Manually Actuated
Spring Offset
DCV

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Control of a Double Acting

Hydraulic Cylinder
Three Position
Four Way
Manually Actuated
Spring Centered
DCV

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Regenerative Circuit
Qt

Pressurized fluid
discharge returned
to system
Speed up
extending speed
Retraction bypass
DCV

Extend

Retract

Qr

Qp

Qt = Qp + Qr

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Drilling Machine Application

Spring centered
position Rapid
spindle advance

Left envelope
Slow feed

Right envelope
Retracts piston

MEL334: Low Cost Automation

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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

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MEL334: Low Cost Automation

Double Pump Hydraulic System

Punch Press
Initial Low
Pressure high
flow rate req.
When punching
operation begins,
increased
pressure opens
unloading valve
to unload low
pressure pump.

Relief
Valve

Unload
Valve

MEL334: Low Cost Automation

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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.

MEL334: Low Cost Automation

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Hydraulic Cylinder Sequence

Circuit
Left Env: Left Cyl
extends completely
and then Right Cyl
extend.
Right Env: Right Cyl
retracts fully and
then Left Cyl
retracts.

MEL334: Low Cost Automation

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Automatic Cylinder Reciprocating

System

Two sequence
valve sensing
strokes completion
by corresponding
pressure build up.

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Locked Cylinder using Pilot Check

Valves

Lock Cylinder so that

piston can not move
by external load.

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10

Cylinder Synchronizing Circuit

Cylinders connected in parallel

Loads identical Moves in exact synchronization
Loads Not exactly Identical (practical situation)
Cylinders also not exactly identical (packing Friction)
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Cylinder Synchronizing Circuit

Cylinders connected in Series

For two cylinder to be synchronized
Piston Area of Cyl 2 = Piston Area of Cyl 1Rod area
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Cylinder Synchronizing Circuit

Pump pressure should overcome load

acting on both cylinders.
P1Ap1- P2(Ap1-Ar1) = F1
P2Ap2- P3(Ap2-Ar2) = F2
MEL334: Low Cost Automation

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Cylinder Synchronizing Circuit

Q. For the Cylinder Synchronizing Circuit, what pump
pressure is required if the cylinder loads are 22kN
each and cylinder 1 has a piston area of 65 cm2?

Ap2 = Ap1-Ar1
P3 = 0
P1Ap1 = F1+F2

MEL334: Low Cost Automation

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12

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

MEL334: Low Cost Automation

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Fail Safe Circuit with Overload

Protection

DCV-1 controlled by Push button

valve-2.
When Overload Valve -3 is in
spring offset mode, it drains the
pilot line of valve 1.
If Cyl experience excessive
resistance, Valve-4 actuates
overload valve -3. This drains
pilot line of Valve1, causing it to
return to spring offset mode.
Nothing happen if push button 2
pressed unless overload valve
shifted manually into blocked
configuration.

MEL334: Low Cost Automation

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13

Two hand Safety Circuit

Designed to protect
an operator from
injury.
For circuit to
function, operator
must depress both
manually actuated
valves.
Any one button
prevents operation.

MEL334: Low Cost Automation

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Speed Control of a Hydraulic Motor

Hydraulic Motor Rotary Motion
Spring Center Position

Motor

hydraulically locked

Left Envelop
Rotates

Clockwise

Right Envelop
Rotates

Anticlockwise
MEL334: Low Cost Automation

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Speed Control of a Hydraulic Motor

MEL334: Low Cost Automation

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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.
MEL334: Low Cost Automation

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Hydraulic Motor Braking System

MEL334: Low Cost Automation

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Hydrostatic Transmission

Open Circuit Drives

Pump

draws fluid from reservoir

Pump output directed to Hydraulic Motor
Discharge from Motor into reservoir

Closed Circuit Drive

Exhaust

oil from the motor returned directly to

pump inlet.

MEL334: Low Cost Automation

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Closed Circuit One-Direction

Hydrostatic Transmission

Closed Circuit that

allows only one direction
of motor rotation.
Motor speed varied by
changing pump
displacement.
Torque capacity of motor
adjusted by pressure
setting of the relief valve.
MEL334: Low Cost Automation

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Closed Circuit Reversible Direction

Hydrostatic Transmission

MEL334: Low Cost Automation

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