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Hydraulic Actuators (Continued) : 1.5acceleration and Deceleration of Cylinder Loads
Hydraulic Actuators (Continued) : 1.5acceleration and Deceleration of Cylinder Loads
HYDRAULIC ACTUATORS[CONTINUED]
Cylinders are subjected to acceleration and deceleration during their operation. Cylinders are decelerated
to provide cushioning and cylinders are accelerated to reduce the cycle time of the operation.
1.5.1 Acceleration
To calculate the acceleration of cylinder loads, the equations of motion must be understood.Let u be the
initial velocity, v the velocity after a time t,s the distance moved during the time t anda the acceleration
during the time t.The standard equations of motion are as follows:
v u at
v2 u 2 2as
1
s ut at 2
2
1
and s (u v)t The force F to accelerate a weight W horizontally
2
with an acceleration a is given by
Force = Mass × Acceleration
W
F= a
g
where g is the acceleration due to gravity and is 9.81 m/s2. The force P required to overcome friction is
given by P = µW, where µ is the coefficient of friction.
Note: Dynamic cylinder thrust
In dynamic applications, the load inertia, seal friction, load friction, etc., must be allowed for calculating
the dynamic thrust.As a first approximation, the dynamic thrust can be taken as 0.9 times the static thrust.
Cylinder seal friction varies with seal and cylinder design. The pressure required to overcome seal friction
is not readily available from the majority of cylinder manufacturers. The seal friction breakout pressure
can be taken as 5 bar for calculation purposes. It reduces when the piston starts to move. The pressure
required to overcome seal friction reduces as the cylinder bore size increases and varies according to the
seal design.
Example 1.3
A cylinder is required to move a 10 kN load 150 mm in 0.5 s. What is the output power?
Example 1.4
A cylinder is required to extend at a minimum speed of 0.75 m/s in a system with a flow rate of 60 LPM.
What cylinder size is required?
1
Solution:
Let us first convert the LPM to :
60 60
Q 60 LPM m3 / min 103 m3 / s
1000 1000 60
Now we know flow rate and velocity, so we can calculate the diameter,
Q Ap v
103 Dp2 0.75
4
Therefore,
4 103
Dp 41.2 mm
0.75
Example 1.5
An 8 cm diameter hydraulic cylinder has a 4 cm diameter rod. If the cylinder receives flow at 100 LPM
and 12 MPa, find the (a) extension and retraction speeds and (b) extension and retraction load carrying
capacities.
Solution:
Let us first convert the flow in LPM to m3/s before we calculate forward velocityQin=100
LPM = 100/(1000 × 60) =1/600 m3/s
Now
DC = Diameter of cylinder = 8 cm = 8 × 10−2 m
dr = Diameter of piston rod = 4 cm = 4 × 10−2 m
p = 12 MPa = 12 × 106 N/m2 or Pa
2
Fret p ( Ap Ar )
106 [(8 102 ) 2 (4 102 ) 2 ]
12
4
42238.9 N 45.24 kN
Example 1.6
A pump supplies oil at 0.0016 m3/s to a 40 mm diameter double-acting hydraulic cylinder. If the load is
5000 N (extending and retracting) and the rod diameter is 20 mm, find the
(a) Hydraulic pressure during the extending stroke.
(b) Piston velocity during the extending stroke.
(c) Cylinder kW power during the extending stroke.
(d) Hydraulic pressure during the retracting stroke,
(e) Piston velocity during the retracting stroke.
(f ) Cylinder kW power during the retracting stroke.
Solution: We have Qin = 0.016 m3/s, Fext = Fret = 5000 N, dC = 40 mm = 0.04 m, dr = 20 mm = 0.02 m.
(a) Hydraulic pressure during the extending stroke is
Fext 5000 5000
pext 3978.8 kPa
Ap dC (0.04)2
2
4 4
(b) Piston velocity during the extending stroke is
Qin Qin 0.016
vext 1.273 m/s
Ap dC2 (0.04) 2
4 4
(c) Cylinder kW power during the extending stroke is
Pext Fext vext 5000 1.273 6.366 kW
4 4
(e) Piston velocity during the retracting stroke is
Qin 0.016
vret =1.697 m/s
Ap Ar (0.042 0.022 )
4
(f) Cylinder kW power during the retracting stroke is
Pret Fret vret 5000 1.697 8.488 kW
Example 1.7
A hydraulic cylinder has a rod diameter equal to one half the piston diameter. Determine the difference in
load-carrying capacity between extension and retraction stroke if pressure is constant. What would
happen if the pressure were applied to both sides of the cylinder at the same time?
3
Retracting stroke is
Fret p ( Ap – Ar )
Also, given that
dp = 2dr
Therefore
Ap = 4Ar
Now
Fext p Ap
Fret p ( Ap – Ar )
Ap
Ap – Ar
Ap
Ap –0.25 Ap
Fext 4
Therefore,
Fret 3
Again
Fext Fret pAp p( Ap –0.25 Ap )
Ap
pAp p Ap
4
pAp
Fext Fret
4
Therefore,
Pr essure Piston area
Difference =
4
If the pressure were applied to both sides of the cylinder at the same time, there would be a net force to
extend the cylinder. This net force will be the same as obtained above:
Pr essure Piston area
Fnet-extending =
4
Example 1.8
A cylinder with a bore of 150 mm and a piston rod diameter of 105 mm, has to extend with a speed of 7
m/s, pressure applied is 150 bar. Calculate
(a) The flow rate in LPM of oil to extend the cylinder
(b) The flow rate in LPM from annulus side to extend the cylinder.
(c) The retract speed in m/min using (a).
(d) The flow rate from full bore end on retract.
4
Hence, Ap Ar 0.00901 m2 .
Given, vext = 7 m/min and p = 150 bar.
(a) Flow rate of oil to extend in LPM:
(Qext ) p Ap vext
0.01767 7
0.12369 m3 /min 123.69 LPM
(b) Flow rate of oil to extend from annulus in LPM:
(Qext )a ( Ap Ar ) vext
0.00901 7
0.06307 m3 /min 63 LPM
(c) Retract speed in m/min using (a):
Qret (Qext )p ( Ap Ar ) vret
0.12369 0.00901 vret
vret 13.728 m/min
(d) Flow rate from full bore end on retract:
Qret Ap vret
0.01767 13.728
0.06587 m3 /min 65.87 LPM
1. Vertical cylinder: Ina vertical cylinder, the load to be actuated is in the vertical direction as
shown in Fig. 1.12. Then the cylinder load F is equal to the weight W of the object, acting in the
vertical direction.
Load
= Cylinder force
2. Horizontal cylinder:The schematic diagram of horizontal cylinder is shown in Fig. 1.13. Ina
horizontal cylinder, the cylinder load is theoretically zero,because no component of the object’s
weight acts along the axis of the cylinder. However, when the object slides across the horizontal
surface, the cylinder must overcome the frictional force created between the object and the
horizontal surface.
5
Load
=W
= Cylinder force
Example 1.9
Find the cylinder force required to move a 6000 N weight along a horizontal surface at a constant velocity
(Fig. 1.15). The coefficient of friction between the weight and horizontal support surface is 0.14.
6
Load
Figure 1.15
Example 1.10
Find the cylinder force required to lift a 6000 N weight along a direction that is 30° from the horizontal
direction as shown in Fig. 1.16. The weight is moved at a constant velocity.
= Cylinder force
Figure 1.16
Solution: Let
Fload = W = weight or load acting vertically downward
Fcyl = load acting on the cylinder
Fbear = force on the bearings
= angle between the load W and the axis of the cylinder
Then
Fcyl = Floadcos
Fbear = Floadsin
Hence,
7
Fcyl 6000 cos60 3000 N
Example 1.11
A 6000 N weight is to be lifted upward in a vertical direction for the system shown in Fig. 1.17. Find the
cylinder force required to
(a) Move the weight at a constant velocity of 1.75 m/s.
(b) Accelerate the weight from zero velocity to 1.75 m/s in 0.5 s.
Load
= Cylinder force
Figure 1.17
Solution:
(a) For a constant velocity, the cylinder force to move weight at a constant velocity of 1.75 m/s
Fcyl Fa W 6000 N
(b) Force required to accelerate the weight:
First we shall calculate acceleration
1.75 0
a 3.5 m/s2
0.5
Force required to accelerate the weight is
6000 3.5
Fa m a 2140.67 N
9.81
The cylinder force Fcyl required is equal to the sum of the weight and acceleration force
Fcyl 6000 2140.67 8140.67 N
Example 1.12
A 10000 N weight is to be lowered by a vertical cylinder as shown in Fig. 1.18. The cylinder has a 75 mm
diameter piston and 50 mm diameter rod. The weight is to decelerate from 100 m/min to a stop in 0.5 s.
Determine the required pressure in the rod end of the cylinder during the deceleration motion.
8
10000 N
Figure 1.18
Solution: As per Newton’s law of motion, we have
F m a
where
m 1min
100
a min 60 s 1.67 m/s 3.34 m/s 2
0.5 s 0.5 s
Summing forces on the 10000 N weight, we have
10000 N
p( Ap Ar ) 10000 N 2
3.34 m/s 2
9.81m/s
p (N/m2 ) (0.0752 0.0502 ) m2 10000 N 3408 N
4
Solving we get
p 5450000 (N/m2 ) 5450000 Pa 5450 kPa
Example 1.13
A 27000 N weight is being pushed up on an inclined surface at a constant speed by a cylinder, as shown
in Fig. 1.19. The coefficient of friction between the weight and the inclined surface equals 0.15.
(a) Determine the required cylinder piston diameter for the pressure of 6894 kPa,
(b) Determine the required cylinder piston diameter, if the weight is to accelerate from a 0 mm/s to a 1524
mm/s in 0.5 s.
9
27000 N
Figure 1.19
Solution:
(a) Cylinder piston diameter for the pressure of 6894 kPa
The component of the weight W acting along the axis of the cylinder is W sin 30. The component of
weight W acting along normal to the incline surface is W cos30. The frictional force equals the
coefficient of friction times the force normal to sliding surfaces.
Therefore, the frictional force f acting along the axis of the cylinder is
f W cos30
0.15 27000 cos30
3507 N
As per Newton’s law of motion, we have calculate the acceleration
F m a
where
10
1524mm/s
a 3048 mm/s2 3.048 m/s 2
0.5 s
Summing forces on the 27000 N weight using values determined in (a), we have
27000 3.048
pAp 17007
9.81
2 27000 3.048
6894000 D 17007
4 9.81
5414535 D2 17007 8389
D = 0.0685 m = 68.5 mm
Example 1.14
A hydraulic cylinder has a bore of 200 mm and a piston rod diameter of 140 mm. For an extend speed of
5 m/min, calculate
(a) The supply flow rate.
(b) The flow rate from the annulus side on extend.
(c) The retract speed using QE.
(d) The flow rate from the full bore end on retract.
Also, if the maximum pressure applied to the cylinder is 100 bar, calculate the (e) dynamic extend
thrust and the (f) dynamic retract thrust assuming that dynamic thrust = 0.9 static thrust.
Moreover, the hydraulic cylinder having a bore of 200 mm diameter and a rod of 140 mm diameter
are connected regeneratively. (g) If the same flow rate of 157 L/min is used, calculate the extend
speed. (h) If the maximum system pressure is 100 bar, calculate the dynamic extend thrust.
Solution:
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0.00262
v= = 0.614 m/s = 9.8 m/min
0.01602
(d) Flow from the full bore end of cylinder QR is given by
Q = A×v= 0.03142×0.164 = 0.00515 m3/s = 309 LPM
(e) We have
0.22
Full bore area = = 0.0314 m 2
4
Dynamic extend thrust = 0.9 × Pressure × Full bore area
= 0.9 × 100 × 105 × 0.0314 2 m2
N
m
= 283 kN
(0.22 0.142 )
(f) Annulus area =
4
= 0.016 m 2
N
Dynamic retract thrust = 0.9 × 100 × 105 × 0.016 2 m2
m
= 144 kN
0.142
(g) Piston rod area = = 0.0154 m 2
4
Flow rate
Extend speed =
Piston rod area
157 103 L m3
=
0.0154 min L×m2
= 10.2 m/min
This compares with 5 m/min when connected conventionally.
(h) For a regenerative system
N
Dynamic extend thrust = 0.9 ×100 × 105 × 0.0154 2 m2
m
= 138.6 kN
As the area of the annulus is almost equal to that of the rod, the regenerative extend and conventional
retract thrusts and speeds are almost the same.
Example 1.15
A mass of 2000 kg is to be accelerated horizontally up to a velocity of 1 m/s from the rest over a distance
of 50 mm (Fig. 1.20). The coefficient of friction between the load and guide is 0.15. Calculate the bore of
the cylinder required to accelerate this load if the maximum allowable pressure at the full bore end is 100
bar (take seal friction to be equivalent to a pressure drop of 5 bar). Assume that the back pressure at the
annulus end of the cylinder is zero.
12
Load
P1=100 bar P2 = 0
Figure 1.20
Solution: In this case, u = 0, v = 1 m/s, s = 0.05 m and a is unknown. Using the equation
v2 u 2 2as
We have,
12 02 2a 0.05 a 10 m / s2
The force to accelerate the load is given by
w 2000 9.81
F a 10 20 000 N
g 9.81
The force P to overcome the load friction is given by
P W 0.15 2000 9.81 2943 N
The total force to accelerate the load and overcome friction is
F + P = 20000 + 2943 = 22943 N
The cylinder area required for a given thrust is calculated from
Thrust = Force × Area
The pressure available is pressure at the full bore end of the cylinder minus the equivalent seal break-out
pressure.
Pressure available = 100−5 = 95 bar = 95 ×105 bar
Area is given by
22943
Area
195 105
0.002415 m 2 2415 mm 2
D2
Area
4
where D is the diameter. Comparing the two equations , we get D = 55.4 mm.
The cylinder diameter is thus 55.4 mm. This neglects the effect of any back pressure. The nearest standard
cylinder above has a 63 mm diameter bore.
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