K.L.

E Society’s
KLE Technological University
School of Mechanical Engineering

HYDRAULICS EXPERIMENTS

KLE Technological University, Hubballi-31

BOSCH REXROTH CENTRE OF COMPETENCE
IN AUTOMATION TECHNOLOGY

Laboratory In charge

Prof. Vivek Komalapur

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HYDRAULIC EXPERIMENTS
Experiment 01
Characteristic Curve of Variable Displacement Hydraulic Pump

Aim: To study hydraulic pump, its characteristics and calculate the hydraulic power

Definition

In a hydraulic system, fluid flow generators/hydraulic pumps convert the mechanical energy of a
drive motor (torque, speed) into hydraulic power (flow, pressure).
Hydraulic pumps are displacer pumps, the displacement of which can be either fixed or variable.
Hydraulic pumps that feature an adjustable displacement are called variable displacement pumps.
The displacement/flow is adjusted by means of mechanical or electronic control systems.
This experiment is to help the student to understand the following:
• With hydraulic variable displacement pumps, the flow is almost reduced to zero when
the system pressure has been reached.
• Due to the design of a variable displacement pump, internal leakage oil occurs, which is
re-fed to the reservoir through an external leakage oil line.
• The leakage oil flow increases as the resistance rises, which opposes the displacement
in the pressure line of the pump
• The drained leakage oil flow is the power loss of the hydraulic pump.
With the help of the control set up on the training system, the student can recognize that when
the system pressure increases as resistance at the pressure port of the hydraulic pump, the total
displacement reduces. The resistance is realized by means of a hand lever valve, with the system
pressure being sleeplessly variable via a pressure relief valve operated in parallel.
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Table 1.1: Component Selection with parts list

Note: The pilot operated, variable vane pump is not included as individual component in parts list
in table 1.1 It is an integral part of the hydraulic power unit.
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Circuit Diagram Hydraulic pump/characteristic curve of variable displacement pump

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Execution of the experiment

Set-up of the control as described in the following:

1. Mount the components required according to Table 1.1 on the training system in a clearly
arranged manner according the prepared circuit diagram. Connect the hydraulic control
according to hydraulic circuit diagram Fig. 1.1 by means of hoses. For connections, to which
pressure gauges with minimess hose DZ 1.4 are to be connected, use hydraulic hoses DZ25.1
Hand-tighten the pressure gauge measuring lines hand tight at the relevant minimess
connection of the hydraulic hose. The proper and tight fit of hose connections of components
can be easily checked by slightly turning the hoses.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on,
check, whether all pressure control valves are set to minimum pressure (spring unloaded) and
all throttle valves are open.
Completely close throttle valve item 1.1. To this end, turn the adjustment element clockwise
to the mechanical limit stop. Close shut-off valve item 1.2.
2. Switch the hydraulic pump on, check and set up control for any leakage.
3. Adjust the system pressure on pressure relief valve item 1.0 to 50 bar plus one turn.
4. Check the set pressure on the variable displacement pump of the drive power unit (zero
stroke pressure 50 bar).
5. Open shut-off valve item 1.2.

6. Open throttle valve item 1.1 until a pressure of 20 bar is present at measuring point M1.

7. Measure the flow using the measuring glass; to this end, close shut-off valve item 1.2, close
the measuring glass, open shut-off valve item 1.2 for 1 liter. Record the filling quantity and
enter the measured value in Table 1.2
8. Take flow measurements as described in points 6 and 7, at pressure values of 25 bar, 30 bar,
40 bar, 45 bar and 50 bar and enter the recorded measured values in Table 1.2
9. After completion of practical work, switch the hydraulic pump on the training system off.
Turn pressure relief valve item 1.0 back to minimum pressure. Open throttle valve item 1.1
completely. None of the pressure gauges should indicate a pressure!
10. Calculate the measured oil flow/time and enter it as flow in qv = lts/min in table1.2.
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Table 1.2: Measurement oil volumes

Pressure Volume in mm³ Time in s Lt/min m³/min

p V t
1 lt
1 lt
1 lt
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11. Enter the individual values as points and connect the individual points with a line to create a
curve. The resulting curve is the typical characteristic curve of the pilot operated, variable
vane pump.
12. Calculate the hydraulic power, P in kW
13. Evaluate the results

Characteristic Curve of the Hydraulic Pump

14. Conclusion
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Experiment 02

Pressure Intensification

Aim: To Study pressure intensification of a single-rod cylinder

Definition

If in a hydraulic system the hydraulic force, which is converted into mechanical energy, is to be
transmitted to an actuator in the form of a linear (straight) movement, a hydraulic cylinder is
used. The hydraulic cylinder as output element forms the link between the hydraulic circuit and
the working element/tool in a technological system. Lifting, lowering, locking and transporting
loads are typical applications of hydraulic cylinders.

The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to vary the piston velocity. In this project, the student is to work out
the physical basic principles of pressure intensification with single rod cylinders. On the basis of
this experiment, he/she is to understand the following:

• The hydraulic cylinder performs a straight movement and transmits the supplied piston
pressure in the form of force.
• Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
• Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
• Forces and velocities can be kept constant over the entire stroke.

Based on the control set up on the training system the student is to learn that the use of a meter
out throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can be
varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished with
the help of a 4/2 directional valve.
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Experiment definition
A work piece is to be shifted by a horizontally installed single-rod cylinder to the working range
of a simple fixture when the hydraulic pump is switched on. To this end, the extension velocity
of the cylinder must be adjustable. Retracting is to be achieved by means of a 4/2 directional
valve. The installed throttle valve on the piston rod side and, while adjusting the extension
velocity, recognizes that the pressure upstream of the throttle becomes higher than the set system
pressure.

Practical example: Hydraulic cylinder of tie rod design

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Table 2.1: Component Selection with parts list

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Single-rod cylinder/pressure intensification

Hydraulic Circuit Diagram

Fig 2.1
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Electrical Circuit Diagram for Pressure Intensification

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Execution of the order

1. Mount the components required according to Table 2.1 in a clearly arranged form on the
training system according to the prepared circuit diagram. Connect the hydraulic control
according to hydraulic circuit diagram Fig. 2.1 by means of hoses. For connections, to
which pressure gauges with minimess line DZ 1.4 are to be connected, use hydraulic hoses
DZ 25.1 Hand-tighten the pressure gauge measuring lines at the relevant minimess connection
of the hydraulic hose. The correct and proper fit of the component connections with hoses can
be checked by slightly turning the hoses.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Check the pressure set on the variable displacement pump of the drive power unit (if
required, correct to 50 bar).
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn; operate push-
button S2 to prevent the piston of hydraulic cylinder Item 1.0 from extending.
5. Through operation of push-button S1 the control voltage of solenoid Y1 of the 4/2 directional
valves Item 1.1 drops, and the piston of the hydraulic cylinder extends due to the pump flow
supplied directly to the piston side.
6. Switch the hydraulic pump off and wait until the system is depressurized. Close throttle
valve Item 1.3. To this end, turn in the adjustment element counter-clockwise to the limit stop.
7. Switch the hydraulic pump on. The piston of the hydraulic cylinder cannot extend, because
the counterforce on the piston rod side is greater than the force on the piston side, since the
throttle valve is closed. Pressure gauge M3 indicates the value of pressure intensification. Note
the measured values and enter them in Table 2.2.

Table 2.2
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8. After having completed practical work on the training system switch the hydraulic pump off!
Turn pressure relief valve Item 1.2 back to minimum Caution pressure. No pressure gauge
may indicate a pressure!

9. Evaluate the results

.
Note: Calculation of pressure intensification on the basis of given hydraulic cylinder values.
Example:
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Experiment 03

Meter-in and Meter-out circuits

Aim: To study concepts of Meter-in and Meter-out circuits using Single-rod

cylinder and 4/2 DCV

Definition

If in a hydraulic system the hydraulic force, which is converted into mechanical energy, is to be
transmitted to an actuator in the form of a linear (straight) movement, a hydraulic cylinder is
used. The hydraulic cylinder as output element forms the link between the hydraulic circuit and
the working element/tool in a technological system. Lifting, lowering, locking and transporting
loads are typical applications of hydraulic cylinders.
The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to vary the piston velocity. In this experiment, the student is to
work out the physical basic principles of pressure intensification with single rod cylinders. On
the basis of this experiment, he/she is to understand the following:
• The hydraulic cylinder performs a straight movement and transmits the supplied piston
pressure in the form of force.
• Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
• Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
• Forces and velocities can be kept constant over the entire stroke.

Based on the control set up on the training system the student is to learn that the use of a meter-
out throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can be
varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished with
the help of a 4/2 directional valve.
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Table 3.1: Component Selection with parts list

Item Qty Component Type Symbol

Designation Designation
Double acting
1.0 1 cylinder with single ZY1.3
sided piston rod
4/2 Directional valve
1.1 1 with solenoid DW3E
actuation with spring
return
Direct operated
1.2 01 pressure relief valve, DD1.1
the cracking
pressure can be
adjusted by means of
a spring
Throttle check valve,
1.3 01 adjustable, DF 2.2
free flow in one
direction

Distributor plate DZ 4.1

01 with four ports

Pressure gauge with DZ 1.4

0.1-0.3 03 hose and quick
release coupling
without check valve
Hose with quick DZ 25.1
03 release coupling
with check valve

Hose VSK1
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Meter-in-Circuit Task-1

Meter-out-Circuit

Meter-out circuit

Fig: 3.1
Meter-out circuits Task-2
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Fig: 3.2
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Electrical circuit diagram for Meter-in and Meter-out circuit

Fig 3.3
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KLE Technological University
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Execution of the experiment

1. Mount the components required according to Table 3.1 in a clearly arranged form on the
training system according to the prepared circuit diagram. Connect the hydraulic control
according to hydraulic circuit diagram Fig.3.1 by means of hoses. Wire the electrical control
according to wiring diagram Fig 3.3
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve to 50 bars plus one turn.

Task 1: Meter-in throttle: Piston side extending

4. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder extends
within 5 s; to this end operate push-button S2. Enter the pressure values (during extending) on
piston side M2 and on piston rod side M3 in Table 3.4
Task 2: Meter-out throttle: Piston rod side extending
5. Convert the hydraulic control according to Hydraulic circuit diagram Fig. 3.2 Repeat
working steps 2 and 3.
6. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder extends within
5 s. To this end actuate push-button S2. Enter the pressure values (during extending) on piston
side M2 and on piston rod side M3 in Table 3.4

Table 3.4: Measurement results from the execution of the order

Measuring points —> M2 p in bar M3 p in bar

Meter-in throttle, piston side -
during extending
Meter-out throttle, piston
rod side -during extending
Meter-in throttle, piston side
«- during retracting
Extending Extending
Meter-out throttle, piston rod side
EEEEEEEEEextendin
«-
g during retracting

7. Evaluate the results

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Experiment 04

Center Configuration of 4/3 DCV

Aim: To study the application of different center configuration of 4/3 DCV

Definition: If the travel, direction, start, and stop of a hydraulic cylinder are to be controlled in a
hydraulic system, a directional valve must be used. Directional valves are differentiated as
follows: directional spool valves, direct operated, pilot operated and directional poppet valves.
Directional valves are elements that assume the task of opening, closing or changing the flow
paths in hydraulic systems.

With the help of the control set up on the training system the student gets familiar with the
possible application of a 4/3 directional valve. A hydraulic cylinder is to be controlled alternately
by a 4/3 directional valve with different spool shapes (blocked and circulation position). The
student can recognize the special features of different symbols by measuring the different
pressure differentials across the 4/3 directional valve. Internal leakage can be recognized by the
horizontal arrangement of the single-rod cylinder, on which no external forces act.
 With a valve is in the blocked position:
– A connected single-rod cylinder can extend due to internal leakage of the valve while the valve
is in its rest position and the pump is running.
– The total flow of a fixed displacement pump flows via the pressure relief valve to the tank
when the set system pressure is reached while the pump is running and the valve is in its rest
position, i.e. high power losses incur and the oil heats up.
– The working pressure utilized last slowly decreases via the clearance of the spool when the
hydraulic pump is switched off and the valve is in its rest position.
 With a valve is in the circulation position:
– When the valve is in its rest position and the pump is switched on the total pump flow flows
almost at zero pressure to the tank; the backpressure and hence the power loss is determined by
the pressure differential across the valve;
Energy is saved while the pump is running and the valve is in its rest position. This feature
cannot be installed in controls, where the system pressure is required by further actuators.
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Experiment Definition
A single-rod cylinder is to shift and position tools horizontally in a fixture. When in the rest
position the hydraulic cylinder must not move, and the fixed displacement pump is to be spared
and thus energy saved. The customer wants to be informed about the pros and cons of the various
spool shapes, in particular blocked and circulation position. In order that the customer can
understand your proposed solution, he requires technical documentation such as the hydraulic
circuit diagram with parts list, and the required measured data for the spool shapes/symbols.
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Table 4.1: Component Selection with parts list

Item Qty Component Designation Type Designation Symbol

1 Double acting cylinder with
1.0 single sided piston rod ZY1.3
1 4/3 directional valve with direct
1.1 actuation by two solenoids, DW 4E
spring
centering of the central position
and central position P - T, A, B

1 4/3 directional valve with direct

1.2 actuation by two solenoids,
spring DW 13E
centering of the central position
and central position P, T, A, B

01 Direct operated pressure relief

1.3 valve, the cracking pressure can DD1.1
be adjusted by means of a spring
01 Throttle valve, adjustable DF 1.2
1.4

01 Distributor plate with four ports DZ 4.1

03 Pressure gauge with hose and DZ 1.4

01-0.3 quick release coupling without
check valve

03 Hose with quick release coupling DZ 25.1

with check valve

Hose VSK1
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4/3 DCV-Tandem Centre Task-1

DAC Single Rod Type; Dp=25mm; Dr=16mm; S=400mm

Fig 4.2
4/3 DCV-Closed Centre Task-2
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Fig 4.3
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Fig: Electrical circuit diagram for Tandem-Closed and Open

Fig 4.4
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Execution of the experiment

Set up the control as described below:
1. Mount the components required according to Table 4.1 in a clearly arranged form on the
training system according to the prepared circuit diagram.
2. Connect the hydraulic control according to hydraulic circuit diagram Fig 4.2 by means of
hoses.
3. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
4. Set the system pressure on pressure relief valve Item 1.3 to 30 bar. By actuating push-button
S3 solenoid Y1b of 4/3 directional valve Item 1.1 is energized. The pump flow is fed against
the piston rod side of hydraulic cylinder Item 1.0 and the system pressure can be set to 30
bar.
5. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized. The
piston of the hydraulic cylinder extends.
Measurements for task 1:
6. Measure the specified values in the end positions of the hydraulic cylinder and in the rest
position (central position) of the 4/3 directional valve as listed in Table 4.5 and enter the
values in Table 4.5
7. Modify the hydraulic control according to hydraulic circuit diagram 4.3 Proceed as
described in task one, steps 1 and 2.
Check the electrical control for correct wiring.
8. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge

may indicate a pressure.

9. Set the system pressure on pressure relief valve Item 1.3 to 30 bar.
10. By actuating push-button S3 solenoid Y1b of 4/3 directional valve Item 1.2 is energized. The
piston of hydraulic cylinder Item 1.1 extends. By actuating push-button S2 the piston of the
hydraulic cylinder retracts. In contrast to task 1, positions "a“and "b“of the 4/3 directional valve
are exchanged due to the spool shape/symbol.
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Measurements for task 2:

10. Measure the specified values in the end positions of the hydraulic cylinder and in the rest

position (central position) of the 4/3 directional valve as listed in Table 4.6 and enter the values

in Table 4.6

Measured values for Task 1

Table 4.5

Measured values Task 2

Table 4.6

11. Evaluate the results

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Experiment 05

Regenerative Circuit

Aim: To study the application of Regenerative Circuit

Definition
On a machine tool the velocity of a feed cylinder is to be increased and thus the cycle time of the
system shortened without changing the pump flow. The advance velocity (extending time of the
hydraulic cylinder) is to be adjustable independently of the load. In order that the student can
understand the circuit structure of the control, he requires the associated documentation such as
the hydraulic circuit diagram with parts list. He/she also requires a table of the travel times of the
hydraulic cylinder with different flow control settings. Moreover, the student wants to know
which effect the increase in the cycle time has on the advance force.

Fig. 01: Practical example: Control block with hydraulic components such as directional,
pressure and flow control
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Component selection parts list

Table. 01: Parts list for hydraulic circuit diagram

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Hydraulic circuit diagram

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Electrical circuit diagram

Fig. 03: Electrical circuit diagram

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Execution of the order

Set up the control as described below:

1. Mount the components required according to parts list Table.1 in a clearly arranged form

on the training system according to the prepared circuit diagram. Connect the hydraulic

control according to hydraulic circuit diagram Fig. 2 by means of hoses.

2. For connections, to which pressure gauges with minimess line DZ 1.4 are to be

connected, use hydraulic hoses DZ 25.1. Hand-tighten the pressure gauge measuring lines

at the relevant minimess connection of the hydraulic hose. The correct and proper fit of

the component connections with hoses can be checked by slightly turning the hoses.

3. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure

gauge may indicate a pressure. Set the system pressure on pressure relief valve Item 1.3

to 50 bar plus one turn.. Set flow control valve Item 1.2 to scale position 1.0. Extend

hydraulic cylinder Item 1.0 by operating push-button S1. Measure the extension time;

enter the extension time and pressures M3 and M2 at the end position of hydraulic

cylinder Item 1.0 in Table.2.

4. Operate push-button S1, which causes the piston of hydraulic cylinder Item 1.0 to retract

again; enter the retraction time of the piston and pressures M3 and M2 at the end position

of hydraulic cylinder Item 1.0 in Table.2. Set flow control valve Item 1.2 successively to

scale positions 1.2, 1.4, 1.6, 1.8 and 2.0 and enter the individual measuring results in

Table.2 as described under point 3. Enter the calculated traversing velocities of the feed

cylinder as characteristic curve in Fig.4

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5. Measured values
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