ME 1022 FLUID POWER CONTROL

HYDRAULIC / PNEUMATIC
CIRCUIT
UNIT IV
 UNIT IV - DESIGN OF FLUID POWER
SYSTEMS
● Speed, force and time calculations, Calculation of pressure
and pressure drop across components, sizing of
actuators, pumps, reservoirs and accumulators.
Calculations of Heat generation in fluids. Design of
hydraulic/pneumatic circuit for practical application,
Selection of different components such as reservoir,
various valves, actuators, filters, pumps based on design.
hydraulic/pneumatic circuit – Simple reciprocating,
Regenerative, Speed control (Meter in, Meter out and bleed
off), Sequencing, Synchronization, transverse and feed,
cascading circuit(two and three cylinders), automatic
reciprocating, fail safe circuit, counter balance circuit,
actuator locking.
 Problem.1
● A hydraulic cylinder is to compress a car body in
10 seconds. The operation requires a stroke of
3m and a force of 40,000N. if a 7.5 N/mm2 pump
has been selected, find the following.

● Required piston area and piston dia.

● The necessary pump flow.
● The hydraulic power capacity in kw.
 Problem.2
● A pump supplies oil at 20 gallons/min to 50 mm
dia double acting cylinder. If the load acting
directly the extension and retraction stroke is
5000 N and diameter of the rod is 25mm .
Find
● Hydraulic pressure during extension stroke.
● The piston velocity during extension stroke.
● The cylinder kw power during extension stroke.
● Hydraulic pressure during retraction stroke.
● The piston velocity during retraction stroke.
● The cylinder kw power during retraction stroke.
 Problem.3
● An accumulator has a ram of 200 mm diameter
and a lift of 6m. If the hydraulic fluid is supplied
at 60 bar, find the

i) The necessary load on the ram and

ii) capacity of the accumulator.
 Problem.4
● A hydraulic circuit has been designed to crush a
car body into a bale size using 175 mm diameter
hydraulic cylinder. The hydraulic cylinder is to
extend 2.4 m during a period of 10s.The time
between crushing stroke is 6min. The
accumulator has the following details. Gas
precharge pressure 90 bar. Gas charging
pressure when pump is turns on 225 bar.
Minimum pressure to actuate load 125 bar.
● Calculate the required size of the accumulator.
● What are the pump flow requirements and the
pump hydraulic kw power with and without
accumulator.
 Problem.5
● A gas loaded accumulator has the following data
precharge pressure = 125 bar, charge
accumulator pressure (or Max Pressure) =200
bar. Pressure falls from 200 bar to 175 bar when
20 lit of oil discharged.

● What is the size of the accumulator?

● Take charging and discharging process as
isothermal.
 Problem.6
● A gas loaded accumulator is used to supply 8000
cm3 of oil with a maximum pressure of 225 bar
and a min pressure of 140 bar. If the nitrogen
precharge pressure is 95 bar, find the size of the
accumulator. The cylinder piston diameter is 200
mm.
 Various circuits are
● Speed control circuits (meter-in, meter-out &
bleed off)
● Simple reciprocating and automatic
reciprocating circuits
● Synchronization and simple sequencing circuits
● Cascading circuits
● Rapid traverse and slow feed circuits
● Regeneration circuits
● Fail Safe Circuits
● Actuator Lock circuits
In sequencing of two cylinder were done Using limit
switches.

The circuit was designed and constructed as per this

sequence i.e A+ B+ A- B- using limit switches.

Let us try to design a circuit for another sequence

i.e. A+ B+ B- A-
Overlapping of signals
OVERLAPPING OF SIGNALS
Signal Overlap can occur when simultaneously two active
signals appear on both set and reset pilot ports of Final Control
Valve.
This is due to the required sequencing of cylinder.
At the start, both signals appear at the same time. This will
not result in any change.

To overcome this we go by Cascade Method.

 Cascade rules
● Establish the correct sequence
● Divide the sequence in to groups. Always start a
sequence with the Run/End valve selecting
group l e.g.
R/E | A+ B+ | B- C+ | C- A-
● Select the cylinder building blocks
● Select the cascade building block
Cascading Method of Signal Elimination
Reversing Valves [Double piloted 5/2 way or 4/2 way] are
signal processing valves which are used to change over from
one signal to next signal.
Depending on the presence of set or reset signal at the
reversing valves, output change over takes place from port 4 to
port 2 of the valve
There is no need to examine exact step where signal over lap
occur in the circuit .
input signal S1 using a reversing valve and the same process
continues.
 Conditions for Cascading
•• Number of signal inputs [from limit switches] must be equal
to number of output signals [pilot signals to final control
valves]
• Each input signal is assigned to a particular out put signal
• It should be possible to store an out put signal even when the
corresponding input signal is no longer present
• Only one out put signal may exist at any one point or it must
be possible to eliminate any specific output signal
• The input signal should be effective in the same required
sequence
• No. of reversing valves required are (n-1), where n is the
number of groups
•Number of pressure signal lines required = n
 Cascade two group
● The A+ B+ B- A- circuit is ● Because only one group
solved by the two group output is available at a
cascade method time it is not possible to
● The sequence is divided have opposed signals
at the point where B ● A standard 5/2 double
immediately returns pressure operated valve
● The two parts are is the cascade valve
allocated groups l and ll
● Gp l A+ B+ / Gp ll B- A- Group l Group ll

● Two signal supplies are 4 2

14 12
provided from a 5/2 valve
one is available only in Select l 5 1 3 Select ll
group l the other is
available only in group ll
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+ B+ Gp ll B- A-
Run/End

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+ B+ Gp ll B- A-
Run/End

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+ B+ Gp ll B- A-
Run/End

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+ B+ Gp ll B- A-
Run/End

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+ B+ Gp ll B- A-
Run/End

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+ B+ Gp ll B- A-
Run/End

a0 b1
 Cascade building blocks
● A two group building
block consists of a lever
valve to run and end the Gp l
sequence plus the 5/2
double pilot operated Gp ll
4 2
cascade valve 14 12
● For a two group system
5 1 3 Sel ll
consisting of any number Run/End
2
of cylinders this building 10
block and the cylinder 12
3 1
building blocks are all Sel l
that is required to solve
the sequence
 Cascade building blocks
● This three group Gp l
building block
establishes an Run/End
interconnecting
pattern that can Gp ll
be extended to Sel l
any number of Sel ll
groups
Gp lll

Sel lll
 Rapid traverse and slow feed
● During certain forming operation, it is required to
slow the tool during the process
● Therefore the piston should have a
Rapid traverse movement and slow feed movement
❑ these circuits are also called as Deceleration
circuits
Rapid traverse and slow feed
Fail Safe Circuits
Actuator Locking Circuits
Counter balance circuit
Regeneration circuits
 Expression for cylinder
extending speed
● Let Qp - pump flow rate
● Q r – regenerative flow rate from the rod end
● Q T – TOTAL FLOW ENTERS THE BLANK END

● QT = QP + Qr

● V ext = Q P / A r

● V ret = Q P / A p - A r

● Load carrying capacity of cylinder FL = P * A r

 Problem in Regeneration
circuit
● A double acting cylinder is hooked up in a
regenerative circuit. The relief valve setting is
105 bar. The piston area is 150 sq.cm and rod
area is 60 sq.cm. If the pump flow is
0.0016 m3 /sec, find the cylinder speed and load
carrying capacity for the
a. Extension Stroke
b. Retraction Stroke
● Calculations of Heat generation in fluids
(Heat Exchangers)