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Volume5 Study of Hydraulic Circuits PDF
Volume5 Study of Hydraulic Circuits PDF
Khan
B. E. (Mech.)
Tanveer Publications,
Mumbai - 78
CONTENTS
Hydraulic Circuit 10.1to 10.62
A close-loop
close-loop hydraulic circuit has all the basic elements
elements of hydraulic
Feed-back
circuit, such as hydraulic pump, hydraulic valves to control direction, flow Mechanism
and pressure, hydraulic accessories etc. In addition to these component it
also has a feed
f eed back mechanism which continuously
continuously monitors system output.
It generates a signal which is proportional to output, then it compares it with
input or command or reference signal. If the two matches, then there is no
adjustment and the system continue to operate as programmed. If there is a
difference between
between the input command signal and the feed back signal, then
the system has provision and mechanism to correct and adjust the out- put
to match with the command requirement.
CLOSE-LOOP CIRCUIT
An electro-hydraulic servo system is a feed back system which measures
measures
and corrects the output.
b) Open loop circuit:-
In this type of
of circuit, we do not
not get feed back.
1) Open circuit
2) Close circuit
M
In open circuit the fluid is sucked
sucked from reservoir by pump. Fluid passes through
hydraulic component and again exhausted to reservoir. Reservoir has excess OPEN CIRCUIT
quality of fluid then what is required
r equired by hydraulic circuit. And quantity of fluid in
Q
hydraulic circuit could be changed without any restrictions.
M
In close loop, reservoir is eliminated and suction of pump is connected to
Q
exhaust line of circuit. Hence a fixed quality of fluid keeps on circulating in
COLSE CIRCUIT
hydraulic system.
Majority of hydraulic systems are open circuit. Close circuit is used for sophisticated, highly
accurate and compact machineries.
Suppose a hydraulic cylinder of 35 ton capacity has to move a load for distance of 50 cm.
Now said
said circuit
circuit could be made in many
many ways
ways . Four of them are as follow
follow..
TYPE 2
TYPE 1
P M
P M
TYPE 3 TYPE 4
P M
• In first
first system
system actuator moves
moves with
with same speed throughout
throughout it’s
it’s stroke. And
And maxi
maximum
mum working
working
pressure
pressure is availab
available
le from start of stroke, till
till end of strokes.
• In second
second and fourth
fourth system
system,, actuator could
could have
have fast
fast approach
approach and return
return speed
speed and show
show
pressi
pressing
ng speed.
speed. And
And full
full working
working pressure
pressure will
will be availa
availabl
blee in last
last slow
slow pressin
pressing
g operation.
operation.
• In third
third system
system,, we can have high
high speed
speed as well as full
full working
working pressure
pressure throughou
throughoutt stroke. But
accumulator
accumulator takes some
so me time
time for charging.
charging. It cannot give continuous high speed and pressure
p ressure
without charging, and some delay time.
time.
All the four system has their
the ir unique advantage
advantag e and disadvantage;
d isadvantage; similarly
similarly any hydraulic
hydraulic circuit
could be designed in many ways, hence knowing different types of vlaves and components,
compo nents, their
t heir
functions their
the ir cost and knowing
kno wing basic requirement
requirement of hydraulic machine isis must
must before designing
d esigning
hydraulic system.
5
Bill of Material
Sr.No. Name of components Functions
1 Motor Prime mover
2 Pump To deliver oil
3 Relief valve To regulate pressure
4 Direction control valve To control direction of
cylinder
5 Hydraulic cylinder Actuator
4 6 Oil tank Oil reservoir
7 Standard accesories To maintain quality of oil
1 and safety of system
3 P M
2 7 7
7
6 7
W = D2 X 4 X P
35000 = D2 X 0.785 X 70
D = 25.238 cm
Pump capacity = Cross-sectiona cylinder X speed
Cross- sectionall area of cylinder
Q = D2 X X V
4 Where:
= (25.238)2 X
X 160 W = Load (kg.)
4 D = Inside diameter (cm)
= 80001.25 cc per min.
min.
P = Working pressure (kg/cm2)
80 litre
litre per min. V = Velocity of cylinder (cm/min)
Q = Pump discharge (cm3/min)
PXQX100 = System efficiency in percentage
Power of
o f electric
electric motor
motor (kw) =
612 X
70X80X100
= = 11.4
612 X 80
• Hence at 70kg/c2 working
wo rking pressure ID of cycle will
will be 25.238cm,
25.238 cm, pump capacity will be
be 80
LPM, and power of electric motor will be11.4 kw.
• For 200kg/cm2 working
wor king pressure, inside diameter
diameter of cylinder
cylinder and pump capacity
capac ity will
will be
D = 149.308 cm
Q = 28 LPM
Power of electric mot
motor
or remain same.
2
• For 350 kg/cm working pressure, inside diameter of cylinder and pump capacity will be:
D = 11.287 cm2
Q = 16000.98 cm3/min
or 16 LPM
Power of
o f electric motor remains the same.
2 2 2
Working 70 kg/C 200 kg/C 350 kg/C
pressure
Sr.
Sr.
Componets Make Model Cost Make Model Cost Make Model Cost
No
Motor Hindustan 15 HP Rs Hindustan 15 HP Rs Hindustan 15 HP Rs
1. Motors Vertical 21497/- Motors Vertical 21497/- Motors Vertical 21497/-
Rs DPRH-10-3- Rs
3. Relife Valve Yuken BG-06 Polyhydron Rs Polyhydron DPRS-06-S-
3365/- 200 1220/- 400 700/-
Accessories Rs Rs Rs
7. 10000/- 6000/-
8000/-
Rs
8. Total Cost Rs Total Cost
80655/-
Total Cost Rs
143434/- 66155/-
From above example we found that system with high pressure are economical and
low pressure are costly.
With time the cost of component will change. But the difference of cost between smaller,
medium and large size will always be there. Hence in every era the high pressure compact
hydraulic system will be always economical than low pressure bulky system.
• With increase of pressure, size of equipment and cost reduces, but maintenance problem
increases. While at low pressure, size of equipment and cost increases. Hence pressure is
decided carefully considering various factors.
• In case of machine tools, the
t he load on hydraulic cylinders
cylinders are much less as compared to hydraulic
hydraulic
presse
presses.
s. If we select
select high
high workin
working
g pressur
pressuree for them,
them, and
and try to calcul
calculate
ate the dime
dimens
nsion
ion of hydrau
hydrauli
licc
cylinder,
cylinder, then
the n these dimensions may be less than 1 cm or only fewfew centimeters.
cent imeters. Such
S uch thin and small
cylinder
cylinder may not give sta
stabil
bility
ity and maintenance free operation,
opera tion, hence for machine tool, we generally
select low working pressure, that is between 50 to 100 kg/cm2.
• There is no hard and fast rule for selection of working
work ing pressure But in general we have following
range of working
wo rking pressure for various systems in industry.
industry.
Sr.
Sr.
Filed of application Range of Working Pressure
No
2
1. Injecton Moulding Machine 210 - 350 Kg/c
Pump 2
2. 210 - 350 Kg/c
The pressure
pr essure drop
dr op in hydraulic system is
is basically due to
t o resistance
resistanc e to flow.
flow. While
While over coming
co ming
this resistance energy is lost. This loss of energy gets converted into heat, which increases temperature
of working fluid.
fluid. Pressure
P ressure drop
dro p is an undesirable
undesirable phenomena, and following
following are the main causes of
pressure
pressure drop in a hydraul
hydraulicic circui
circuit.
t.
1) Decrease in pump efficiency:-
Pump effici
efficiency
ency decreases due to wear and teart ear of
o f it’s
it’s internal components, or due to rise in
temperature. High temperature increases clearance between pump casing and moving element, element,
through which high
high pressure oil
o il escapes back
back to
t o low pressure side. This cause pressure drop and
further increase in fluid temperature.
2) Throttling in valves:-
valves:-
Valves are designed as perpe r CETOP standard,
sta ndard, and oil hole in them are 6 mm, 11 mm,
mm, 22 mm
etc. These oil holes work like an orifice.
orifice. Whenever large flow passes through
thro ugh a small hole, the
velocity of fluid
fluid increases but pressure
pressur e drops.
dro ps. Similarly
Similarly when fluid
fluid passes through
t hrough hydraulic valves,
valves,
there is some drop in pressure due to throttling.
throttling.
3) Internal leakage
leakage in valve:-
Direction control
cont rol valve
valve has a sliding
sliding spool in valve
valve body. Due to constant
co nstant use
u se sliding
sliding contact
conta ct
area wears out.
out . As
As clearance increases internal leakage increases. When high pressure fluid leaks
leaks
through
throug h these clearances, it causes drop
dro p in pressure, and flui
fluid
d heating.
What we have described for direction control
co ntrol valves also hold good for all valves
valves with
sliding
sliding spool and poppet
po ppet and with metal to metal sealing
sealing arrangement.
arrange ment. (sealing by fine
fine clearance)
4 )Valves
)Valves with spring loaded poppet:-
popp et:-
Construction
Const ruction of some valves are such that whenever fluid
fluid passes through
thro ugh them, then
t hen it has to lift
lift
a spring loaded
loaded spool
spoo l or poppet or
o r steel ball etc. Whenever fluid
fluid pressure acts against such spring
force to over-come compression of spring spring then some energy is is lost and pressure drops. Such
valves are pressure
pressu re reducing valves,
valves, sequence valves, check valves,
valves, pilot operated
operat ed check valves,
relief valves etc.
5) Resistance to flow
flow through pipe line:-
Fluid experiences resistance to t o flow while passing through pipe line, joints and bends etc.
Hence there
ther e is pressure drop
d rop at
a t every joint and bend in pipe line.
line. While passing through pipe line
due to such resistance energy of fluid
fluid is lost and pressure drops.
drop s.
• Pressure
Pressure drop is studied
studied carefull
carefully
y and
and calcula
calculated
ted to ascertain
ascertain the heat
heat generation
generation in
in system,
system,
because
because pressure drop reduces the system
system effi
efficien
ciency
cy,, and heat
heat which
which get generated
generated damages
damages the
system. Hence special steps are taken
ta ken at design stage to control
co ntrol and keep both of them in safe
limit.
At every valve,
valve, joint, and bend etc. pressure drop
dr op could
co uld be calculated with help of technical
data available
available in
in design book. Once we get total
tot al pressure drop, heat generated could be calculated.
12
9
7 8
5
4
10
P 11
2
1
Total pressure drop at fast speed and low pressure will be.
be.
2
2 kg/cm - cracking pressure o f check valve
valve (1)
2
2 kg/cm - main direction
direction control
co ntrol valve (6)
2
2 kg/cm - pilot operated check valve (7)
5kg/cm2 - hydraulic cylinder
cylinder (12)
2
2kg/cm - direction
direction control valve
valve to control
co ntrol flow
flow (9)
2
6kg/cm - check valve to develope back pressure to operated direction control valve
valve (10)
2
2kg/cm - pressure
pressur e drop in return line
line filter
filter (11)
21 kg/cm2
Total pressure drop at low speed
spe ed and high pressure will bebe
2
2kg/cm - cracking pressure of check valve (4)
2kg/cm2 - cracking pressure of
o f pilot
pilot operated
o perated check valve
valve (7)
5kg/cm2 - pressure drop across
a cross flow control valve (8)
2
5kg/cm - pressure drop due to
t o seal friction
friction in cylinder
cylinder (12)
14 kg/cm2
After calculating
calculating total pressure drop
dro p heat generation
ge neration is calculated
calculated using followin
following
g equations.
equat ions.
10X60XPXQ
H=
427
Where H = Heal in Kcal/hr
P = Pressure drop kg/cm2
Q = Flow of pump in lpm
10X60X21X90
In present example
example heat generated
generat ed is = =2655.7kcal/hr
427
m x s x (t1-t2) X 60 = H (kcal/hr)
Where m = mass of fluidfluid (LPM)
S = specific heat of fluid.(it
fluid.(it is 1 for water and 0.85 for mineral
mineral oil)
t1-t2= Temperature difference of fluid before and after cooling.
10.7 Sequence
Sequence and Cycle Diagram
Very few power packs are operated by hand. hand. Most of the power
po wer packs are controlled
and actuated
actuat ed by electrical control panel. Press design, hydraulic
hydraulic circuit design,
design, hydraulic power
pack manufacturin
anufacturing,g, assembl
assembly y and testing,
testing, commi
commississionin
oning,g, and maintenanc
maintenance,
e, all
all these jobs are
done by different
different engineers. For better
bet ter comm
co mmunication
unication and understanding among them there should
be some
some bluepri
blueprint
nt which
which all
all should
should read, understan
understand d and interpr
interpretet without
without any diff
differe
erence.
nce.
Hence for this purpose along with circuit
circuit diagram, sequence chart and load cycle diagramdiagram
is also
also made. Sequence
Sequenc e chart contains,
cont ains, sequence of energisation of various solenoid, and their
controll
contro lling
ing parameter. Whil
Whilee load cycl
c yclee diagram indicates
indicates stroke
s troke,, load developed and tim
t imee required.
requ ired.
An example of sequence chart and a nd load cycle diagram for a deep drawing press is as
follow.
Pressure switch
15
4 PS1
13
12 LS
11 1
Limit LS 3
switches
LS 10
2
Blank-hilding
cylinder
S2 S3 S
8 4 9 S5
S1
Unloading
valve 6
4
15 16
P V M 15
14LPM 70LPM 15
250BAR 20BAR 15HP
16
17
Figure No. 35.25
Hydraulic Circuit Diagram of Deep Drawing Press
2. Two pum
pumps areare use
used d in whi
which low pres
pressusure pump2 is unload
re pum unloadeded by unloading valve, which
5
is actuated, and control
contro l by a solenoid
solenoid valve
valve . (S1)
3. For deep
deep draw
drawiing operati
operation on shee
sheet-m
t-metal
etal blank
blank is place
placed d on press-
press-tab
tablele manual
anuallly. On
pressi
pressing
ng push-bu
push-buttontton blan
blank-h
k-holdi
olding
ng cyl
cylinder
inder moves
moves forward
forward,, and presses
presses the sheet-m
sheet-metal
etal
blank.
blank. Load
Load isis sensed by pressure switch (PS1), which gives gives signal
signal to main
main cylinder
cylinder to
take its forward stroke.
4. The depth
depth of drawdraw produc
produceded by
by forwa
forward rd stroke
stroke of mai
mainn cyl
cyliinder
nder is
is sens
sensed
ed by
by (Lim
(Limit
switch) LS2, and this this stops forward stroke
st roke and activate return stroke.
5. Compl
Completietion
on of return
return stroke
stroke is sensed
sensed by limi
limitt switch
switch LS3 and it stops return
return stroke
stroke and
and
activate return
ret urn stroke
str oke ofo f blank-holding
blank-holding cylinder.
cylinder.
6. Return
Return stroke
stroke of blank
blank-hol
-holdi
ding
ng cyl
cylin
inder
der is
is sens
senseded by limi
limits
ts swi
switch
tch LS1.
LS1. It stops
stops the
the return
return
stroke of blank-holding cylinder.
7. Eject
Ejection
ion is automa
automati ticc and
and achi
achieved
eved by mecha
mechani nical
cal mean
means.s. Linka
Linkages
ges are
are provi
provided
ded by
by whi
which
ch
the returning
ret urning platen of blank-holder
blank-holder also eject the drawn component.
component . Drawn component
removed manually and new blank-loaded manually. This makes press ready for next
operation.
SEQUENCE OF S1 S2 S3 S4 S5 CONTROLS/
OPERATION ACTUATION
ACTUATION BY
Start of Cycle
ON OFF OFF ON OF
OFFF Push-botton
Blank-holding Cylinder
Cylinder
Forward Stroke (Manual)
Blank-holding Cylinder
Cylinder ON OFF OFF OFF ON LS3
Return Stroke
Completion of
ReturnStroke and End of OFF OFF OFF OFF OF
OFFF LS1
Production
Product ion Cycle
Cycle
Cycle Diagram: -
,
g
n
i
s
n
e .
s p
e
r m
u
s u
s p
r e
e r
p u
c s
i s
l e
r
u
a p
r
d w
o
y l
H f
)
l o
a g
d c i
i n d d d
e
t r d
t e
t e
t e
t
a c a a a a
u
t e l
l o u
t u
t u
t
c c c c
A - n
E u A A A
1 n d 2 3 1
o n S S S
S N
P ( A L L L
n g
n
0
0
7 w r a w i
d
S l o
o
F
r
e
a
s
d h t
n
i o c
r
e
l r t
y p u
c a p
r
n
n e
i
a
k
o i d
r
t a p
M S R
0
4 Tank
1
3
2
P M
1
Example of a Modular Valve stacked
Figure No. 35.22
Figure No. 35.21
Above mention circuit is general hydraulic circuit
circuit diagram. For modular valve same above
circuit can also be drawn in following
following ways.
A-port
B-port
P A
Direction control Direction
Pipe line valve (4) control
T B
valve (4)
Tank line
Pilot opareted
Check valve (6)
Check valve
Relief valve
for Pump (3)
7) We have
have drawn
drawn abov
abovee circui
circuitt diag
diagram
ram for
for one
one valve
valve bank
bank (set
(set of
of a valv
valve)
e).. More
More num
number of
valves bank could be added on manifold, using same pump and tank. If a relief valve, pilot
operated check valve, flow control valve and direction control valve is further added to operate
one more cylinder in same power pack with common pump and motor, then new circuit diagram
will be as follow.
Direction controll P A P A
Direction controll
valve
valve
T B T B
P P Manifold or
T
T
B B
A A
Tank New Cylinder Cylinder Pump
Actuators
Oil Tank
Pumping Unit
Control units
Actuators
Motor and Pump
assembly
Oil Tank
1. There should
should be alw
alway
ayss a relie
relieff val
valve
ve to control the maxi
maximum
mum pressure
pressure of the system
system..
Relief valve should be immediately
immediately after pump, so that
t hat due to any
a ny reason if oil flow
flow generated
generated
by pump gets blocked
blocked then it can pass through relief
relief valve,
valve, without
without damagin
damaging g any other
parts of the system
system..
Pressure relief valve
P M
Figure No 10.11.1
2. When
When two pumps
pumps are usedused in
in a system
system in which
which one
one pump
pump is
is with
with high
high flow
flow and
and low
low
working pressure for fast approach
appro ach and return speed, and second pump
p ump is with
with low flow
capacity and high
high working pressure
pres sure for actual pressing
press ing operation.
operat ion. Then after reaching
certain pressure high flow
flow pump is required to be unloaded to tank to avoid excessive
excessive load
on prime-mover. For such application “Unloading type relief valve” is used as shown in
following circuit diagram.
Figure No 10.11.2
P M P
Figure No 10.11.3
In a hydraulic
hydraulic circuit when different
different pressures are required at different
different stage of
o f operation, then
t hen
following
following type of
o f arrangement of direction control
co ntrol valve and pressure relief valve could be used.
If pressure
pressur e setting
set ting of ‘Pressure
‘Press ure Relief Valve-A
Valve-A’’ and ‘Pressure Relief
R elief Valve -B’ are lower than
system pressure,
pressur e, then when solencid-1
so lencid-1 is energized,
energized , then maxium pressure in system will will be as per
Pressure
Press ure Relief Value
Value -A and when solenoid-2
solenoid- 2 is energized then
the n maximum
maximum pressure
pressu re in system will
be as per Pressure
Pressure Relief
Relief Valve-B
alve-B.. And when
when both the solenoi
solenoids
ds are switched
switched off then maxi
maximum
mum
pressure
pressure wil
will be as per setting
setting of relief
relief valve-C
valve-C.. Unloadi
Unloading
ng reli
relief valve
valve D in circui
circuitt 35.2 will
will only
only
control pressure of low pressure pump. (Fig 35.2)
C B A
Sol. 2
A
Sol. 1
C D
High pressure
pilot Line
P M P
Many time
time hydraulic
hydraulic presses are required
requ ired to hold
ho ld the job under compression for very long
period
period of time.
time. For
For such operation if motor
oto r runs continuously
continuously to develop
develop pressure
pressure for pressing
pressing
operation
operat ion then it will bebe uneconomical
uneco nomical,, due
d ue to excessive electric consumption. Also oil will will get
heated up,
u p, as most of the pump
pu mp discharge will
will pass through
thro ugh the relief valve.
valve.
For such application
application pilot
pilot operated check valve is used in circuit.
circuit. Which hold the pressurized
oil in cylinder
cylinder or
o r system
syste m for
for long
lo ng time. A simple circuit of this
t his type is as follow.
fo llow.
P M
Figure No 10.12.1
For return
retu rn stroke-pilot
stroke-pilot pressure is
given to unlock the pi
pilot
lot operated
oper ated
check valve and release pressure in
cylinder
P M
Pressure
Pressur e released from cyli
cylinder
nder for return
retur n stroke.
Figure No 10.12.2
10.13 Decompression
Decompression Circuit
a) Decomp
Decompre
ressi
ssion
on circuit
circuit using
using an
an ori
orific
ficee and
and che
check
ck valve.
valve.
In following circuit
circuit diagram
diagra m when pump develops pressure,
press ure, no oil will
will flow through
throug h check
valve. Only in neutral position of solenoid operated direction control valve, pressurized oil of
cylinder
cylinder will slowly
slowly press over check valve to tank.
t ank. Due to
t o orifice the release o
off pressurized oil
o il will
will
be very
very slow.
slow. This
This arrange
arrangem ment cannot
cannot be used when there
there is alway
alwayss a pressure
pressure in pump
pump line.
line. (Fig.
(Fig.
No. 35.4)
P M
Figure No 13.1
b) Decompression circuit using orifice and solenoid operated direction control valve.
P M
Figure No 13.2
(Pressure held in first
first cylinder
cylinder is getting
gett ing De-compressed)
Status of Pressure in Neutral Position
Position after forward stroke
c. Decompr
Decompress ession
ion with
with in-buil
in-buildd featur
featuree in valves:
valves: -
Pilot operated
oper ated check
che ck vale, pre-fill valves etc. can also have decompression
deco mpression feature in their
basi
basic desi
design. When
When such
such valve
valvess are used,
used, they automa
automatitical
cally
ly reduce
reduce pressur
pressuree gradual
graduallly. Detai
Details
of such valve have been described in chapter
chapter No. 31.
d. Decompr
Decompressi
ession
on by directio
direction
n control
control valve:
valve:
Finit Position
Spool
Spoo l of direction
direction control
cont rol valve
valve changes
its position from one finite
finite condition to another
a nother
in fract
fraction
ion of a second. In tra
transit
nsit condition the
pressuri
pressurized
zed port may get connected
connected to tank as
explained in following figure. This causes a
sudden drop
dro p in pressure resulting in large sound Transite position in which
and vibration. all port are connected to tank.
Figure
Figure No 13.3
Pilot valve
Main Direction
control valve
Orifice
Back pressure get
developed
develope d in system due
P M to orifice.
Figure No 13.4
By using backpressure valve we can exactly vary and select the backpr essure. While by
using a check valve back pressure will be fixed
fixed and as per
p er the cracking pressure
pres sure of spring of check
valve.
Main directio
direction
n
Pilot Valve
Valve Opereted
Operet ed by
controll
cont roll Valve
Valve
Back Pressure
A B
P Y
Orifice
Orifice to develop
Back Pressure
P M
Back pressure
pre ssure in system by using orifice.
orifice. In place orifi
o rifice
ce a check valve also
could be used.
An orifice
orifice should
shou ld always
always be used after
afte r a relief valve, so that if any dust particle
p article get struck
s trucked
ed
in orifice,
orifice, then
t hen build-up
build-up pressure will not damage
d amage the pumpp ump and system.
Main directio
dir ection
n
controll
contr oll Valve
Valve
Pilot Valve
Back Pressur
P ressuree Valve
Valve
P M
Back pressure
pressu re in system
system as per
setting of
o f Counter Balance Valve,
Valve,
which holds the load in position.
Check Valve
Valve for free reverse
rev erse flow
P M
Status
Stat us of pressure in
in natural position after
after forward stro ke.
Check-Valve
Check-Valve for free reverse
rever se flow
P M
Forward stroke
Figure
Figure No. 10.15.2
Check-Valve
Check-Valve for free reverse
reve rse flow
Load
P M
Clamp
Cylinder
Sequence
Valve
P M
Clamp Cylinder
Sequence Valve
P M
Clamp Cylinder
Sequence Valve
P M
Clamp Cylinder
Sequence
Valve
P M
10.17 Direction
Directi on Control circuit
Hydraulic Circuit For Actuating Number of cylinder with common Motor and Pump:-
When more than one cylinder is used in a system,
system, and
an d all the cylinders are required
requ ired to be
actuated
actua ted independently
independe ntly,, then more than one
o ne direction control
contr ol valve inin circuit is
is required. If the basic
basic
requirement of circuit is that when cylinders are not actuat
a ctuated
ed (in idle
idle condition), pump
p ump should be
unloaded to tank. And
And when cylinders
cylinders are actuated
actu ated then
t hen only pressure gets developed.
developed . This could
be achieved
achieved in number
number of ways
ways as follow.
ollow.
a. Usin
Usingg Ten
Tendu
dum m typtypee dir
direc
ecti
tion
on cont
contrrol valv
valvee in
in ser
serie
ies:
s: -
P M
Figure
Figure No. 10.17.1
Status
Stat us of pressure in neutral position after
after forward stroke.
str oke.
b) Hydraulic
Hydraulic circuit to operate
operate more number of cylinders
cylinders using all-port-block
all-port-block valve
valve and
solenoid operated unloading valve.
In this circuit all the cylinders
cylinders can
ca n have high pressure.
When none-of the cylinder is actuated, unloading valve will unload pump discharge to tank.
When any solenoid operated
oper ated direction
directio n control
contro l valve
valve gets activated,
activated , solenoid valve of unloading
valve
valve should also be actuated
actuate d to develop pressure in system.
system.
When lever
lever operated
opera ted direction control
co ntrol valves are used then addition direction control
contro l valve
valve is
used in place of unloading
unloading valve to unload thet he pump when not in used, and to develop
d evelop pressure
when required. Pressure
Pres sure developing direction control
cont rol valve is
is always operated
oper ated with all the
direction
direction control valves.
valves.
1
2 3 4
When solenoid
valve no. (1) get
de-energised oil
passes to tank via
via
pil
pilot operate
operatedd P M
relief valve.
Oil passing
passing to tank
tan k at
atmospheric pressure
through
throug h this valve in
neutral position
1 2 3 4
P M
B
2
1
P M
B
2
1
1
2
P M
Figure No .10.18-B
Forward stroke under pressure
Oil will
will not pass
pa ss through
throu gh check valve (2), because
becaus e there is higher
higher pressure
pr essure on
o n pump side.
side.
B 2
1
P M
Figure
Figure No. 10.18-C
Return stroke
Pressure is locked
locked in for-
ward pipe line, Because
direction control valve
keeps the
t he oil locked in cyl- B
inder port in neutural po-
sition
P M
a) When after
after dev
devel
elopi
oping
ng pres
pressur
suree cyl
cylinder
inder does
does not
not have
have to travel
travel any
any long
longer
er,, as in
in case
case of
coining, embossing etc. then an orifice
orifice provided
pro vided parallel to check valve reduces
reduc es the build-up
build-up
backpress
backpressure.
ure. But this
this also
also reduces
reduces forward
forward speed
speed slig
slightl
htly
y. Because
Because from
from return port some
oil escapes from orifice
orifice and returns
ret urns to tank
t ank (instead of
o f getting mixed
mixed with pump discharge).
P M
throatel
B
2
1
P M
Figure
Figure No. 10.18-F
Forward stroke
under pressure
pres sure and fast movement (before coini
co ining
ng and forming
forming operation)
o peration)
1 2
P M
(A-Port side of
o f piston
piston area is larger
larger than B-port side of piston area Hence a slight pressure on A
side develops high pressure ono n B side. Oil on high pressure gets
get s mixed
mixed with oil on lower
lower pres-
p res-
sure through check valve No.2)
b) In followi
following
ng circui
circuitt as
as soon as some
some pressure
pressure gets developed
developed at A-port, oil comin
coming
g out from
from
B-port gets unloaded to tank through
thro ugh unloading relief
relief valve. Hence backpressure gets
get s mini-
mini-
1 2
P M
figure
figure No. 10.18-H
10. 18-H
Forward stroke under pressure
(After
(After facing
facing resistance when pressure o f A-port side increased more than B-port side, oil stops
mixing
mixing through
thro ugh Check Valve
Valve No.2)
No. 2)
mized.
“Design and Manufacturing of Hydrauli
Hydrauli c Presses.”
Presses.” ©: Q.S. Khan
Khan 10-43
Study of Hydraulic Circuit Regenerative Circuit
A
B 2
Relief Valve
Valve for B-p
1 2
Pressurised
Pressurised oil
o il of B-port under pressure
p ressure
gets
get s released to
t o tank via Check Valve
Valve
No.2
P M
P M
Figure
Figure No. 10.18-J
Return stroke
P M
Forward stroke.
P M
Reverse stroke.
Back pressure in
returen line of
motor.
Back pressure
valve
P M
Q
Loss of
o f energy in Meter
Meter-in-type
-in-type will be
be
M
PxQ2 _ (P-P1)xQ1
Le = (Kw)
612 612
Figure No 10.20.1
P A1 A2 P2
Q1
F
P=
A1
PxQ2
Loss of energy = Le = (Kw)
612
In bleed-off type circuit the loss of
o f energy is less
less
than meter-in or meter-out type
t ype of circuit.
circuit.
P
Q Many time
time different
different speed of actuator
actuat or required
re quired
M
using single pump. In such situation foll
fo llowing
owing
circuits are used dependin
dep ending
g on
o n requirement
Figure No 10.20.3
4) Two
Two speed circuit:-
circuit: -
In this circuit we have option of having full
A1 TWO SPEED CIRCUIT speed, which we achieve by by-passing
by-passing flow
F control
contro l valve.
valve. Or we can have controlled speed
Direction
by using
using flow
flow control
control valve.
valve. Directi
Direction
on control
c o n t r o l valve No.2 we use forfo r by-passing or blocking
valve 2
the flow
Q
M
Figure No 10.20.4
FV1
DIRECTION
CONTROL
FV2 VALVE 2
5) Two
Two control speed:-
speed :-
In previous circuit we had one full speed and
second controll
contro lled
ed speed. But if we want to
P have two controlled speed then followng
followng cir-
cuit is used.
Q
M In neutral position
po sition of direction control valve
No.2. WeWe have speed as per setting
setting of flow
flow
control
contr ol valve number
number - FV1 .And when direc-
Figure No 10.20.5 tion control
cont rol valve
valve No.2 is energised
energised then we
have speed as per combined
combined setting ofo f FV1 &
FV2.
A DCV in
energies
high speed
condition
Flow
Control
hence oil flow
through flow
FV2 B
control Valve
Valve isolatede
because of
colenoid valve FV1
in de-energised
conditions.
M P M
P
Figure No 10.20.2
Forward stroke.
Figure No 10.20.1
Figure No. Forward stroke (First slow speed)
C D
P M
P M
Figure No 10.20.4
Figure No 10.20.3
Return stroke.
Status of Pressure in Neutral Position
after forward stroke
In this circuit we have used meter-in
type flow-c
flow-contro
ontroll valves.
valves. To
To have two speed
spe ed
of actuator we have used one more flow
control
cont rol valve along with a solenoid valve in
parallel
parallel with first
first flow
flow control valve.
valve. Same
arrangement can be used for meter-out
meter-o ut as well
as Bleed-off circuit.
• In position 2 we by-pass FV2. Hence get medium speed as per setting of FV1 .
• In 3 rd
rd posi
positi
tion
on,, we
we get
get spe
speed
ed as per
per combi
ombine
ned
d set
setti
tin
ng of
of FV1 & FV2.
FV1
1 2 3
FV2
Q
M
• Three
Three speed also
also could
could be achieved
achieved by
by using
using fol
followi
lowing
ng circui
circuitt diagram
diagram..
A1
F
S3
Q
FV 3 M
FV1 FV 2 FV 3 FV 4
S1 S2 S3 S4
8) Continuous speed
speed control (Autometic speedspeed control):-
control):-
To have continuous
continuous speed control
co ntrol as per the demand of process, we have to use proportional
pro portional
electro-hydraulic flow control valve as per following circuit.
10.21 SYNCHRONISATION
SYNCHRONISATION CIRCUIT
By using four flow control valve we can synchronize speed of two-cylinder. But this is not a
foolproof system.
system. Error
Err or may occur and may accumulate
accumulate with every stroke. Hence error after every
stroke must be corrected.
corrected .
One of the method of co rrecting
rrecting error is to provide
pro vide lim
limit
it switches for both forward and return
stroke of both the
t he cylinder
cylinder (Total four limit
limit switches). And when both thet he limit
limit switches at one
o ne end
are actuated
actua ted then only cylinder
cylinder will
will take the
t he next stroke.
strok e. Hence on each stroke
st roke the
t he error difference
in stroke gets corrected.
co rrected. Synchronization
Synchronization could be achieved more accurately by using pressure
and temperature compensated
co mpensated flow
flow control
cont rol valve.
Figure No 10.21.1
By using
using pressure and
a nd temperature
temperat ure compensated
co mpensated flow
flow control
co ntrol valve we can achieve
synchronisation in stroke distance
dista nce up to 95%,
95 %, but stil
st illl 5% variation may
may exist. To avoid cumulation
cumulation
of error in stroke,
stroke , at the end of each stroke error should be corrected.
If each cylinder is provided with individual pump with perfectly same flow, and individual
direction control
cont rol valve, then synchronisation in stroke
str oke could
cou ld be more
more accurat
a ccurately
ely achieved. But if
load on
o n individual
individual cylinder
cylinder are
ar e different
different,, the pump discharge will again vary,
vary, resulting
re sulting in variation in
stroke. In
I n this case also the error should be corrected at end of stroke.
Providin
Pro vidingg individual
individual pump for individual
individual cylinder
cylinder is very costly
co stly option. Hence Tedium gear
pumps
pumps type
type flow
flow divi
dividers
ders are used
used for synch
synchroni
ronisati
sation.
on. In this
this type
type of flow
flow devid
devider
er numb
numberer of smal
smalll
gear pumps ofo f equal discharge are assembl
asse mbleded with single spiddle or shaft. Their suction
su ction is also
common. Hence when they rotate,
rot ate, they
t hey supply equal amount of o f oil from all the pumps, which are
supplied to each actuator.
Visit
Visit the website __www.vivolo.co
__www.vivolo.com_
m_ who is manufacture
manufacturerr of such valve, to understand
underst and
them throughly.
throughly. (Ref. page no. 36-49)
These valves also give good accuracy. But as load on individual cylinder various, variation
in stroke is bound to happen. Hence correction of error
erro r at the
t he end of stroke is unavoidable.
unavoidable.
Nu mber
mb er o f smal
sm alll g ea r
pum
p um ps w it h c o mmo n
sucntion and individual
discharge for equally
dividiing main pump
discharge.(These pumps
are not connected to electric
motor. But only seves as
flow divider. they also could
be considered as hydraul
hydraulicic
gear motor)
Figure No 10.21.2
Doamond Circuit
Figure No 10.21.3
M P
system pressure.
Meter-out type flow controlcon trol
valve is used to control 6
spindle
spindle speed.Meter-out type
9
valve reduces fluctuation in
speed much better than meter-
5
in type circuit,with change in 5
cutting load.
Figure No 10.22.1
10.23 Honning
What is honning?
Honing is simil
similar
ar to internal grinding,
grinding, but in this process instead
instea d of grinding wheel grinding stone
sticks are used and
a nd grinding
grinding stone
st one sticks are rotated
rotat ed as well as reciprocated inside
inside an cylindrical
cylindrical
object to remove material of object as per requirement. In honing, ovalityovality as well as taper of inside
inside
diameter
diameter is corrected.
correct ed. As per the size and grade of honinghoning stone
sto ne stick used for honing
honing we get
surface finish
finish better than
t han grinding process. Honing process
proc ess is generally used iin
n manufacturing of
hydraulic cylinder
cylinder or cylinder of aut
automo
omobil
bilee engine.
High flow high pressure pump :- To reciprocate honing head at required high speed high flow flow
pump
pump is used as per requireme
requirement. nt.
Relief valve regulates pressure of reciprocating cylinder.
Flow control valve controls
contr ols the speed of reciprocat ing cylin
cylinder.
der.
Direction control valve controls
contr ols the direction of reciprocating
recipro cating cylinder.
cylinder.
This simple counter balance valve offers some back pressure pressur e when cylinder
cylinder descends down,
do wn,
HONNING
11 14
10
13
9
12
1
7
2 P M P
Figure No 10.23.1
because
because of this
this speed
speed of cyli
cylinder
nder remai
remains
ns under
under control as per flow control
control valve
valve setting.
setting.
Reciprocating cylinder : - In honing machine
machine up and
a nd down speed of honing head should be
same, hence either cylinder in mode double ended. Or differential cylinder is used along with
regenerative
regenerat ive circuit.
circuit.
Pump with low discharge is used for hydraulic motor o f honing head, as revolving speed of
honing head is between
betwe en 10-70
10-7 0 rpm only,
only, and clampi
c lamping
ng cylinder is
is operat
ope rated
ed only at the beginni
be ginning
ng
operation. Relief valve controls
and at the of operation. contro ls working pressure of pump No. 7
Direction control valve and 12 are used in series because because of two reasons.
a) Flow
Flow is small hence heat
heating
ing will
will be minimum.
minimum.
b) Clam
Clampiping
ng cyli
cylinder
nderss are rarely
rarely used, hence
hence it does not interf
interfere
ere func
function
tionin
ing
g of hydraul
hydrauliic motor.
motor.
If we use all port block valve
valve in such situation, then one more valve
valve we have to add to unload pump
when both hydraulic motor and clampingclamping cylinder
cylinder are not in use. Hence by using two direction
direct ion
control
cont rol valve in
in series we save one valve.
va lve.
Flow control valve , controls
cont rols and varies the speed of hydraulic
hydraulic moto
motorr attached
attac hed to honing head.
Hydraulic Motor 11 :- rotates
rot ates the honing head. By using
using hydraulic motor
moto r in place of general
geared electric moto
motor,r, we have full and easy control over speed and torque torq ue of honing
honing head.
Pilot operated check valve 13 locks the t he clamping
clamping cylinder
cylinder under pressure. Clamping cylinder 14
holds the job firmly,
firmly, as in honing job is subjected to rotary
rot ary torque
to rque as well
we ll as up and
a nd down pulli
pu lling
ng
and pushing force.
In this hydraulic
hydraulic circuit we have used meter in type flow flow contro
c ontroll valve.
valve. Bleed of
o f type is
is also used.
use d.
In bleed-off power loss is comparatively less.
CIRCUIT DIAGRAM OF
Ø 100 x Ø 75 x 5000mt
Lubrication
Lub.Return
M
7/min 95/min
7.5kw
500
Figure No 10.23.2