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
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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 6

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 7

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 8

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

MEL334: Low Cost Automation

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Control of a Double Acting Hydraulic Cylinder

Three Position Four Way Manually Actuated Spring Centered DCV

MEL334: Low Cost Automation

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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

MEL334: Low Cost Automation

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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

MEL334: Low Cost Automation

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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.
MEL334: Low Cost Automation

Relief Valve

Unload Valve

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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.
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MEL334: Low Cost Automation

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 18

Automatic Cylinder Reciprocating System

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

MEL334: Low Cost Automation

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Locked Cylinder using Pilot Check Valves

Lock Cylinder so that piston can not move by external load.

MEL334: Low Cost Automation

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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 23

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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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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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
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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.
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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.
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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.
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Closed Circuit Reversible Direction Hydrostatic Transmission

MEL334: Low Cost Automation

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