Hydraulic Circuit

9 Design and Analysis

Learning Objectives

Upon completing this chapter, you should be able to:

1. Describe the operation of complete hydraulic circuits drawn using graphic

symbols for all components.
2. Troubleshoot hydraulic circuits to determine causes of malfunctions.
3. Determine the operating speeds and load-carrying capacities of regener-
ative cylinders.
4. Discuss the operation of air-over-oil circuits.
5. Understand the operation of mechanical-hydraulic servo systems.
6. Analyze hydraulic circuits to evaluate the safety of operation.
7. Design hydraulic circuits to perform a desired function.
8. Perform an analysis of hydraulic circuit operation, including the effects of
frictional losses.
9. Analyze the speed control of hydraulic cylinders.

9.1 INTRODUCTION

Definition of Hydraulic Circuits

The material presented in previous chapters dealt with essentially fundamentals

and hydraulic system components. In this chapter we discuss hydraulic circuits that
primarily do not use basic electrical control devices such as push-button switches,
pressure switches, limit switches, solenoids, relays, and timers. Similarly, Chapter 14
covers pneumatic circuits that primarily do not use these electrical control devices.
Hydraulic and pneumatic circuits that use basic electrical control devices (shown
both in the fluid power circuits and in separate electrical circuits called ladder

From Chapter 9 of Fluid Power with Applications, Seventh Edition. Anthony Esposito. Copyright © 2009 by
Pearson Education, Inc. Publishing as Prentice Hall. All rights reserved.

 Chapter 9

diagrams) are presented in Chapter 15. Fluid power applications that use advanced
electrical controls such as electrohydraulic servo systems and programmable logic
controllers are presented in Chapter 17.
A hydraulic circuit is a group of components such as pumps, actuators, control
valves, and conductors arranged so that they will perform a useful task. There are
three important considerations when analyzing or designing hydraulic circuits:

1. Safety of operation
2. Performance of desired function
3. Efficiency of operation

It is very important for the fluid power technician or designer to have a work-
ing knowledge of components and how they operate in a circuit. Hydraulic circuits
are developed using graphic symbols for all components. Before hydraulic circuits
can be understood, it is necessary to know these fluid power symbols. Appendix G
gives a table of symbols that conforms to the American National Standards Institute
(ANSI) specifications. Many of these symbols have been presented in previous chap-
ters, and ANSI symbols are used throughout this book. Although complete memo-
rization of graphic symbols is not necessary,Appendix G should be studied so that the
symbols become familiar.The discussions that follow will cover circuits that represent
basic hydraulic technology. Convention requires that circuit diagrams be drawn with
all components shown in their unactuated position.
Figure 9-1(a) provides a photograph of a hydrostatic transmission whose com-
plete hydraulic circuit is given in Figure 9-1(b). This hydrostatic transmission, which
is driven by an electric motor, is a completely integrated unit with all the controls
and valving enclosed in a single, compact housing. Observe that the hydraulic circuit
of Figure 9-1(b) uses graphic symbols for all the hydraulic components of the hydro-
static transmission, including the electric motor, hydraulic pump, hydraulic motor, oil
reservoir, filter, and the various control valves.

Computer Analysis and Simulation

of Fluid Power Systems

There are basically two types of computer software available for solving fluid power
system problems. The first type performs only a mathematical analysis as it deals
with the equations that define the characteristics of the components of the fluid
power system.The second type recognizes the configuration of the entire fluid power
system involved and thus can provide both a simulation of the system as well as a
mathematical analysis.
The first type of software typically involves the programming of the equations
that define the performance of the fluid power system. The operation of the system
and how each component interacts within the system is defined mathematically, know-
ing the equations that define the characteristics of each component.The equations are
programmed using computer software such as BASIC and Mathcad™. Desired input
data is then fed into the computer and output results are printed out to display the


Hydraulic Circuit Design and Analysis

(a) Photograph

(b) Complete hydraulic circuit

Figure 9-1. Hydrostatic transmission. (Courtesy of Sperry Vickers, Sperry Rand

Corp., Troy, Michigan.)

behavior of the fluid power system. With the use of this software, values of parame-
ters such as pump flow rate, pump discharge pressure, and cylinder diameter can be
repeatedly changed until optimum system performance is achieved. Other analysis-
type software packages are available that specifically handle fluid power systems.
One example is HydCalc, which performs a mathematical analysis without the user
having to program equations.


 Chapter 9

The second type of computer software system recognizes the configuration of

an entire fluid power circuit along with the characteristics of each component. This
computer software recognizes the circuit as it is being created by the user on a com-
puter screen. The user selects components from a computer library and hooks them
together via a click, drag, and drop procedure. Mathematical analysis along with cir-
cuit simulation is graphically displayed on a computer screen. The design of the cir-
cuit can be readily modified until an optimum and properly operating system is
obtained. The programming of component and system equations is not required. The
computer software not only provides a mathematical analysis but also provides sim-
ulations of the operation of the fluid power circuit.
Automation Studio™ is an example of the software that provides both system
simulation and mathematical analysis. Chapter 18 discusses the salient features of
Automation Studio and how it is utilized. Also included with this textbook is a CD
that illustrates Automation Studio in action in the design and simulation of 16 of the
fluid power circuits provided throughout this book.

9.2 CONTROL OF A SINGLE-ACTING

HYDRAULIC CYLINDER

Figure 9-2 shows how a two-position, three-way, manually actuated, spring-offset

directional control valve (DCV) can be used to control the operation of a single-
acting cylinder. In the spring-offset mode, full pump flow goes to the tank via the
pressure relief valve. The spring in the rod end of the cylinder retracts the piston
as oil from the blank end drains back to the tank. When the valve is manually actu-
ated into its left envelope flow path configuration, pump flow extends the cylinder.
At full extension, pump flow goes through the relief valve. Deactivation of the DCV
allows the cylinder to retract as the DCV shifts into its spring-offset mode.

Figure 9-2. Control of single-acting

hydraulic cylinder.


Hydraulic Circuit Design and Analysis

9.3 CONTROL OF A DOUBLE-ACTING

HYDRAULIC CYLINDER

Figure 9-3 gives a circuit used to control a double-acting hydraulic cylinder.

The operation is described as follows:

1. When the four-way valve is in its spring-centered position (tandem design), the
cylinder is hydraulically locked. Also, the pump is unloaded back to the tank at
essentially atmospheric pressure.
2. When the four-way valve is actuated into the flow path configuration of the
left envelope, the cylinder is extended against its load force Fload as oil flows
from port P through port A. Also, oil in the rod end of the cylinder is free to
flow back to the tank via the four-way valve from port B through port T. Note
that the cylinder could not extend if this oil were not allowed to leave the rod
end of the cylinder.
3. When the four-way valve is deactivated, the spring-centered envelope prevails,
and the cylinder is once again hydraulically locked.
4. When the four-way valve is actuated into the right envelope configuration, the
cylinder retracts as oil flows from port P through port B. Oil in the blank end
is returned to the tank via the flow path from port A to port T.
5. At the ends of the stroke, there is no system demand for oil. Thus, the
pump flow goes through the relief valve at its pressure-level setting unless the
four-way valve is deactivated. In any event, the system is protected from any
cylinder overloads.

Fload

A B

P T

Figure 9-3. Control of a double-

acting hydraulic cylinder. (This
circuit is simulated on the CD
included with the textbook.)


 Chapter 9

9.4 REGENERATIVE CYLINDER CIRCUIT

Operation

Figure 9-4(a) shows a regenerative circuit that is used to speed up the extending
speed of a double-acting hydraulic cylinder. Note that the pipelines to both ends of
the hydraulic cylinder are connected in parallel and that one of the ports of the
four-way valve is blocked. A common method used to block a valve port is to
simply screw a threaded plug into the port opening. The operation of the cylinder
during the retraction stroke is the same as that of a regular double-acting cylinder.
Fluid flows through the DCV via the right envelope during retraction. In this mode,
fluid from the pump bypasses the DCV and enters the rod end of the cylinder. Fluid
in the blank end drains back to the tank through the DCV as the cylinder retracts.
When the DCV is shifted into its left envelope configuration, the cylinder
extends as shown in Figure 9-4(b). The speed of extension is greater than that for a
regular double-acting cylinder because flow from the rod end (QR) regenerates with
the pump flow (QP) to provide a total flow rate (QT), which is greater than the pump
flow rate to the blank end of the cylinder.

Cylinder Extending Speed

The equation for the extending speed can be obtained as follows, referring to Figure
9-4(b): The total flow rate (QT) entering the blank end of the cylinder equals the
pump flow rate (QP) plus the regenerative flow rate (QR) coming from the rod end
of the cylinder:

QT 5 QP 1 QR

Solving for the pump flow rate, we have

QP 5 QT 2 QR

We know that the total flow rate equals the piston area (AP) multiplied by the
extending speed of the piston 1yPext 2 . Similarly, the regenerative flow rate equals the
difference of the piston and rod areas (AP - Ar) multiplied by the extending speed
of the piston. Substituting these two relationships into the preceding equation yields

QP 5 APyPext 2 1AP 2 Ar 2 yPext

Solving for the extending speed of the piston, we have

QP
yPext 5 (9-1)
Ar

From Eq. (9-1), we see that the extending speed equals the pump flow
rate divided by the area of the rod. Thus, a small rod area (which produces a large


Hydraulic Circuit Design and Analysis

FLOAD
BLOCKED

(a) Complete circuit.

Fload
ext
p
QT = p p
yPext
QP + QR

BLOCKED

QT =
QP + QR

QP QR

(b) Partial circuit showing flow paths during cylinder extension stroke.

Figure 9-4. Regenerative cylinder circuit.


 Chapter 9

regenerative flow rate) provides a large extending speed. In fact the extending speed
can be greater than the retracting speed if the rod area is made small enough.

Ratio of Extending and Retracting Speeds

Let’s find the ratio of extending and retracting speeds to determine under what
conditions the extending and retracting speeds are equal. We know that the retract-
ing speed 1yPret 2 equals the pump flow rate divided by the difference of the piston
and rod areas:

QP
yPret 5 (9-2)
AP 2 Ar

Dividing Eq. (9-1) by Eq. (9-2), we have

yPext QP>Ar AP 2 Ar
QP> 1AP 2 Ar 2
5 5
yPret Ar

On further simplification we obtain the desired equation:

yPext AP
5 21 (9-3)
yPret Ar

From Eq. (9-3), we see that when the piston area equals two times the rod area,
the extension and retraction speeds are equal. In general, the greater the ratio of
piston area to rod area, the greater the ratio of extending speed to retracting speed.

Load-Carrying Capacity During Extension

It should be kept in mind that the load-carrying capacity of a regenerative cylinder

during extension is less than that obtained from a regular double-acting cylinder.
The load-carrying capacity 1Floadext 2 for a regenerative cylinder during extension
equals the pressure times the piston rod area rather than the pressure times piston
area. This is because system pressure acts on both sides of the piston during the
extending stroke of the regenerative cylinder, as shown in Figure 9-4(b). This is in
accordance with Pascal’s law, and thus we have

Floadext 5 pAr (9-4)

Thus, we are not obtaining more power from the regenerative cylinder during
extension because the extending speed is increased at the expense of reduced load-
carrying capacity.


Hydraulic Circuit Design and Analysis

EXAMPLE 9-1
A double-acting cylinder is hooked up in the regenerative circuit of Figure 9-4(a).
The cracking pressure for the relief valve is 1000 psi. The piston area is 25 in2
and the rod area is 7 in2. The pump flow is 20 gpm. Find the cylinder speed,
load-carrying capacity, and power delivered to the load (assuming the load
equals the cylinder load-carrying capacity) during the
a. Extending stroke
b. Retracting stroke

Solution

QP 120 gpm2 1231 in3>1 gal2 11 min>60 s2

a. yPext 5 5 5 11.0 in>s
Ar 7 in2
Floadext 5 pAr 5 1000 lb>in2 3 7 in2 5 7000 lb

Powerext 5 Floadextypext 5 7000 lb 3 11.0 in>s 5 77,000 in # lb>s 5 11.7 hp

231
20 3
QP 60
b. ypret 5 5 5 4.28 in>s
Ap 2 Ar 25 2 7

Floadret 5 p 1AP 2 Ar 2 5 1000 lb>in2 3 125 2 7 2 in2 5 18,000 lb

Powerret 5 Floadretypret 5 18,000 lb 3 4.28 in>s 5 77,000 in # lb>s 5 11.7 hp

Note that the hydraulic horsepower delivered by the pump during both the
extending and retracting strokes can be found as follows:

p 1psi2 3 Qpump 1gpm2 1000 psi 3 20 gpm

HPpump 5 5 5 11.7 hp
1714 1714
Thus, as expected, the hydraulic power delivered by the pump equals the
power delivered to the loads during both the extending and retracting strokes.

Drilling Machine Application

Figure 9-5 shows an application using a four-way valve having a spring-

centered design with a closed tank port and a pressure port open to outlet ports
A and B.


 Chapter 9

A B

P T

Figure 9-5. Drilling machine application.

(This circuit is simulated on the CD included
with textbook.)

The application is for a drilling machine, where the following operations take
place:

1. The spring-centered position gives rapid spindle advance (extension).

2. The left envelope mode gives slow feed (extension) when the drill starts to
cut into the workpiece.
3. The right envelope mode retracts the piston.

Why does the spring-centered position give rapid extension of the cylinder (drill
spindle)? The reason is simple. Oil from the rod end regenerates with the pump flow
going to the blank end. This effectively increases pump flow to the blank end of the
cylinder during the spring-centered mode of operation. Once again we have a regen-
erative cylinder. It should be noted that the cylinder used in a regenerative circuit is
actually a regular double-acting cylinder. What makes it a regenerative cylinder is
the way it is hooked up in the circuit. The blank and rod ends are connected in
parallel during the extending stroke of a regenerative cylinder. The retraction mode
is the same as a regular double-acting cylinder.

9.5 PUMP-UNLOADING CIRCUIT

In Figure 9-6 we see a circuit using an unloading valve to unload a pump. The
unloading valve opens when the cylinder reaches the end of its extension stroke
because the check valve keeps high-pressure oil in the pilot line of the unload-
ing valve. When the DCV is shifted to retract the cylinder, the motion of the pis-
ton reduces the pressure in the pilot line of the unloading valve. This resets the
unloading valve until the cylinder is fully retracted, at which point the unload-
ing valve unloads the pump. Thus, the unloading valve unloads the pump at the
ends of the extending and retraction strokes as well as in the spring-centered
position of the DCV.


Hydraulic Circuit Design and Analysis

Figure 9-6. Pump-unloading circuit.

Fload

PRESSURE
RELIEF
VALVE
HIGH-
PRESSURE
LINE

UNLOADING VALVE

LOW-
FLOW HIGH-
PUMP FLOW
PUMP (DELIVERS NO FLOW TO EXTENDING
CYCLINDER WHEN "HIGH PRESSURE"
EXISTS IN HIGH-PRESSURE LINE DUE
TO PUNCHING OPERATION)
Figure 9-7. Double-pump
LOW-PRESSURE LINE hydraulic system.

9.6 DOUBLE-PUMP HYDRAULIC SYSTEM

Figure 9-7 shows a circuit that uses a high-pressure, low-flow pump in conjunction
with a low-pressure, high-flow pump. A typical application is a sheet metal punch
press in which the hydraulic ram (cylinder) must extend rapidly over a great dis-
tance with very low pressure but high flow-rate requirements. This rapid extension
of the cylinder occurs under no external load as the punching tool (connected to
the end of the cylinder piston rod) approaches the sheet metal strip to be punched.


 Chapter 9

However, during the short motion portion when the punching operation occurs, the
pressure requirements are high due to the punching load. During the punching oper-
ation, the cylinder travel is small and thus the flow-rate requirements are low.
The circuit shown eliminates the necessity of having a very expensive high-
pressure, high-flow pump. When the punching operation begins, the increased
pressure opens the unloading valve to unload the low-pressure pump. The purpose
of the relief valve is to protect the high-pressure pump from overpressure at the end
of the cylinder stroke and when the DCV is in its spring-centered mode. The check
valve protects the low-pressure pump from high pressure, which occurs during the
punching operation, at the ends of the cylinder stroke, and when the DCV is in its
spring-centered mode.

EXAMPLE 9-2
For the double-pump system of Figure 9-7, what should be the pressure
settings of the unloading valve and pressure relief valve under the following
conditions?
a. Sheet metal punching operation requires a force of 2000 lb.
b. Hydraulic cylinder has a 1.5-in-diameter piston and 0.5-in-diameter rod.
c. During rapid extension of the cylinder, a frictional pressure loss of
100 psi occurs in the line from the high-flow pump to the blank end of the
cylinder. During the same time a 50-psi pressure loss occurs in the return
line from the rod end of the cylinder to the oil tank. Frictional pressure
losses in these lines are negligibly small during the punching operation.
d. Assume that the unloading valve and pressure relief valve pressure
settings (for their full pump flow requirements) should be 50% higher
than the pressure required to overcome frictional pressure losses and
the cylinder punching load, respectively.

Solution
Unloading Valve:
Back-pressure force on the cylinder equals the product of the pressure loss in
the return line and the effective area of the cylinder (Ap - Ar).

lb p
Fback pressure 5 50 2
3 11.52 2 0.52 2 in2 5 78.5 lb
in 4

Pressure at the blank end of the cylinder required to overcome back-

pressure force equals the back-pressure force divided by the area of the cylin-
der piston.
78.5 lb
pcyl blank end 5 5 44.4 psi
p
11.5 in 2 2
4


Hydraulic Circuit Design and Analysis

Thus, the pressure setting of the unloading valve should be 1.50(100 + 44.4)psi =
217 psi.
Pressure Relief Valve:
The pressure required to overcome the punching operation equals the
punching load divided by the area of the cylinder piston.

2000 lb
ppunching 5 5 1132 psi
11.5 in 2
p 2
4
Thus, the pressure setting of the pressure relief valve should be 1.50 × 1132
psi = 1698 psi.

EXAMPLE 9-3
For the system of Example 9-2, the poppet of the pressure relief valve must
move 0.10 in from its fully closed position in order to pass the full pump flow
at the PRV setting (full pump flow pressure). The poppet has a 0.75-in2 area
on which system pressure acts. Assuming that the relief valve cracking pres-
sure should be 10% higher than the pressure required to overcome the
hydraulic cylinder punching operation, find the required
a. Spring constant of the compression spring in the PRV
b. Initial compression of the spring from its free-length condition as set by
the spring-adjustment mechanism of the PRV (poppet held against its
seat by spring)

Solution
a. At full pump flow pressure (PRV setting), the spring force equals the
hydraulic force acting on the poppet.
Spring force 5 hydraulic force
lb
kS 5 pPRV settingApoppet 5 1698 3 0.75 in2 5 1274 lb
in2

where
k = spring constant (lb/in),
S = total spring compression (in)
= spring initial compression (l) plus full poppet stroke
= l + 0.10.


 Chapter 9

Substituting the expression for S into the preceding equation yields the first of
two force equations.
k 1l 1 0.102 5 1274 lb
or kl 1 0.10 k 5 1274 lb

We also know that at the cracking pressure of the relief valve, the spring
force equals the hydraulic force acting on the poppet. This yields the second
force equation.

kl 5 pcrackingApoppet 5 11.10 3 1132 lb>in2 2 3 0.75 in2

or
kl 5 934 lb

Substituting the 934-lb value for kl into the first force equation yields
934 1 0.10k 5 1274 or k 5 3400 lb>in

b. We can solve for the initial compression of the spring by substituting the
spring constant value into the second force equation.

3400 lb>in 3 l 1in2 5 934 lb or l 5 0.275 in

9.7 COUNTERBALANCE VALVE APPLICATION

Figure 9-8 illustrates the use of a counterbalance or back-pressure valve to keep

a vertically mounted hydraulic cylinder in the upward position while the pump is
idling. The counterbalance valve (CBV) is set to open at somewhat above the pres-
sure required to prevent the vertical cylinder from descending due to the weight
of its load. This permits the cylinder to be forced downward when pressure is
applied on the top. The open-center directional control valve unloads the pump.
The DCV is a solenoid-actuated, spring-centered valve with an open-center flow
path configuration.

9.8 HYDRAULIC CYLINDER SEQUENCING CIRCUITS

As stated earlier, a sequence valve causes operations in a hydraulic circuit to behave

sequentially. Figure 9-9 is an example where two sequence valves are used to con-
trol the sequence of operations of two double-acting cylinders. When the DCV is
shifted into its left envelope mode, the left cylinder extends completely, and then
the right cylinder extends. If the DCV is then shifted into its right envelope mode,
the right cylinder retracts fully, and then the left cylinder retracts. This sequence of


Hydraulic Circuit Design and Analysis

CBV

LOAD

Figure 9-8. Counterbalance valve

application.

Figure 9-9. Hydraulic cylinder sequence circuit. (This circuit is simulated on

the CD included with this textbook.)


 Chapter 9

Figure 9-10. Automatic

cylinder reciprocating system.

cylinder operation is controlled by the sequence valves. The spring-centered posi-

tion of the DCV locks both cylinders in place.
One application of this circuit is a production operation. For example, the left
cylinder could extend and clamp a workpiece via a power vise jaw. Then the right
cylinder extends to drive a spindle to drill a hole in the workpiece. The right cylinder
then retracts the drill spindle, and then the left cylinder retracts to release the work-
piece for removal. Obviously these machining operations must occur in the proper
sequence as established by the sequence valves in the circuit.

9.9 AUTOMATIC CYLINDER RECIPROCATING SYSTEM

Figure 9-10 is a circuit that produces continuous reciprocation of a hydraulic cylin-

der.This is accomplished by using two sequence valves, each of which senses a stroke
completion by the corresponding buildup of pressure. Each check valve and corre-
sponding pilot line prevents shifting of the four-way valve until the particular stroke
of the cylinder has been completed. The check valves are needed to allow pilot oil
to leave either end of the DCV while pilot pressure is applied to the opposite end.
This permits the spool of the DCV to shift as required.

9.10 LOCKED CYLINDER USING PILOT CHECK VALVES

In many cylinder applications, it is necessary to lock the cylinder so that its piston
cannot be moved due to an external force acting on the piston rod. One method
for locking a cylinder in this fashion is by using pilot check valves, as shown in
Figure 9-11. The cylinder can be extended and retracted as normally done by the


Hydraulic Circuit Design and Analysis

Fload

Figure 9-11. Locked cylinder using

pilot check valves.

action of the directional control valve. If regular check valves were used, the
cylinder could not be extended or retracted by the action of the DCV. An exter-
nal force, acting on the piston rod, will not move the piston in either direction
because reverse flow through either pilot check valve is not permitted under
these conditions.

9.11 CYLINDER SYNCHRONIZING CIRCUITS

Cylinders Connected in Parallel

Figure 9-12 is a very interesting circuit, which seems to show how two identical
cylinders can be synchronized by piping them in parallel. However, even if the two
cylinders are identical, it would be necessary for the loads on the cylinders to be
identical in order for them to extend in exact synchronization. If the loads are not
exactly identical (as is always the case), the cylinder with the smaller load would
extend first because it would move at a lower pressure level. After this cylinder has
fully completed its stroke, the system pressure will increase to the higher level
required to extend the cylinder with the greater load. It should be pointed out that
no two cylinders are really identical. For example, differences in packing friction
will vary from cylinder to cylinder. This alone would prevent cylinder synchroniza-
tion for the circuit of Figure 9-12.


 Chapter 9

Cylinders Connected in Series

The circuit of Figure 9-13 shows that hooking two cylinders in series is a simple way
to synchronize the two cylinders. For example, during the extending stroke of the
cylinders, fluid from the pump is delivered to the blank end of cylinder 1 via the
flow path shown in the upper envelope of the DCV. As cylinder 1 extends, fluid
from its rod end is delivered to the blank end of cylinder 2. Note that both ends of
cylinders and the entire pipeline between the cylinders is filled with fluid. Fluid
returns to the oil tank from the rod end of cylinder 2, as it extends, via the DCV.
For the two cylinders to be synchronized, the piston area of cylinder 2 must equal
the difference between the areas of the piston and rod for cylinder 1. This can
be shown by applying the continuity equation which states that the rate at which
fluid leaves the rod end of cylinder 1 must equal the rate at which fluid enters
cylinder 2. Thus, we have for a hydraulic fluid

Qout1cyl 12 5 Qin1cyl 22

Fload

Fload

Figure 9-12. Cylinders hooked in parallel will not operate in synchronization.

AR
CYLINDER 1 1
F1
p1
p2

Ap
1

AR
CYLINDER 2 2
F2
p2
p3

Ap
2

Figure 9-13. Cylinders hooked in series will operate in synchronization.


Hydraulic Circuit Design and Analysis

Since Q = Aυ where A is the effective area through which fluid flows, we have

1Aeffy2 cyl 1 5 1Aeffy2 cyl 2

thus

1AP1 2 AR1 2y1 5 AP2y2

Since for synchronization υ1 = υ2, we have the desired result:

AP1 2 AR1 5 AP2

It should be noted that the pump must be capable of delivering a pressure equal
to that required for the piston of cylinder 1 by itself to overcome the loads acting on
both extending cylinders. This is shown as follows, noting that the pressures are
equal at the blank end of cylinder 2 and at the rod end of cylinder 1 per Pascal’s law
(refer to Figure 9-13 for area, load, and pressure identifications):
Summing forces on cylinder 1 yields

p1AP1 2 p2 1AP1 2 AR1 2 5 F1

Repeating this force summation on cylinder 2, we have

p2AP2 2 p3 1AP2 2 AR2 2 5 F2

Adding the preceding two equations together and noting that AP2 5 AP1 2 AR1
and that p3 = 0 (due to the drain line to the tank), we obtain the desired result:

p1AP1 5 F1 1 F2 (9-5)

9.12 FAIL-SAFE CIRCUITS

Protection from Inadvertent Cylinder Extension

Fail-safe circuits are those designed to prevent injury to the operator or damage to
equipment. In general they prevent the system from accidentally falling on an oper-
ator, and they also prevent overloading of the system. Figure 9-14 shows a fail-safe
circuit that prevents the cylinder from accidentally falling in the event a hydraulic
line ruptures or a person inadvertently operates the manual override on the pilot-
actuated directional control valve when the pump is not operating. To lower the
cylinder, pilot pressure from the blank end of the piston must pilot-open the check
valve at the rod end to allow oil to return through the DCV to the tank. This hap-
pens when the push-button valve is actuated to permit pilot pressure actuation of
the DCV or when the DCV is directly manually actuated while the pump is oper-
ating. The pilot-operated DCV allows free flow in the opposite direction to retract
the cylinder when this DCV returns to its spring-offset mode.


 Chapter 9

Figure 9-14. Fail-safe circuit.

Fail-Safe System with Overload Protection

Figure 9-15 shows a fail-safe circuit that provides overload protection for system
components. Directional control valve 1 is controlled by push-button, three-way
valve 2. When overload valve 3 is in its spring-offset mode, it drains the pilot line
of valve 1. If the cylinder experiences excessive resistance during the extension
stroke, sequence valve 4 pilot-actuates overload valve 3. This drains the pilot line
of valve 1, causing it to return to its spring-offset mode. If a person then operates
push-button valve 2, nothing will happen unless overload valve 3 is manually shifted
into its blocked port configuration. Thus, the system components are protected
against excessive pressure due to an excessive cylinder load during its extension
stroke.

Two-Handed Safety System

The safety circuit of Figure 9-16 is designed to protect an operator from injury.
For the circuit to function (extend and retract the cylinder), the operator must
depress both manually actuated valves via the push buttons. Furthermore, the
operator cannot circumvent this safety feature by tying down one of the buttons,
because it is necessary to release both buttons to retract the cylinder. When the
two buttons are depressed, the main three-position directional control valve is
pilot-actuated to extend the cylinder. When both push buttons are released, the
cylinder retracts.


 VALVE 3
VALVE 4

VALVE 2

VALVE 1

Figure 9-15. Fail-safe

circuit with overload
protection.

Figure 9-16. Two-handed safety circuit. (This circuit is simulated on the CD included
with this textbook.)


 Chapter 9

9.13 SPEED CONTROL OF A HYDRAULIC CYLINDER

Operation

Figure 9-17 shows a circuit where speed control of a hydraulic cylinder is accom-
plished during the extension stroke using a flow control valve. The operation is as
follows:

1. When the directional control valve is actuated, oil flows through the flow
control valve to extend the cylinder. The extending speed of the cylinder
depends on the setting (percent of full opening position) of the flow control
valve (FCV).
2. When the directional control valve is deactuated into its spring-offset mode,
the cylinder retracts as oil flows from the cylinder to the oil tank through the
check valve as well as the flow control valve.

Analysis of Extending Speed Control

During the extension stroke, if the flow control valve is fully open, all the flow from
the pump goes to the cylinder to produce maximum cylinder speed. As the flow
control valve is partially closed its pressure drop increases. This causes an increase

p1 p2

Qcyl
FCV

QFCV
Qcyl = QFCV

p3 Fload

υcyl

Qpump

QPRV

PRV

Figure 9-17. Meter-in speed control of hydraulic cylinder during extending stroke using
flow control valve. (DCV is in manually actuated position.)


Hydraulic Circuit Design and Analysis

in pressure p1. Continued closing of the flow control valve ultimately results in pres-
sure p1 reaching and exceeding the cracking pressure of the pressure relief valve
(PRV). The result is a slower cylinder speed since part of the pump flow goes back
to the oil tank through the PRV. For the desired cylinder speed, pressure p1 approx-
imately equals the PRV setting, and the amount of pump flow that is not desired
by the cylinder flows through the PRV. An analysis to determine the extending
speed is given as follows:
The flow rate to the cylinder equals pump flow rate minus the flow rate through
the PRV.

Qcyl 5 Qpump 2 QPRV (9-6)

The flow rate through the flow control valve (FCV) is governed by Eq. (9-7).

B SG B SG
¢p p1 2 p2
QFCV 5 Cy 5 Cy (9-7)

where ∆p = pressure drop across FCV,

Cv = capacity coefficient of FCV,
SG = specific gravity of oil,
Pressure p1 = pPRV = PRV setting.

Also, pressure p3 = 0 (ignoring small frictional pressure drop in drain line from
rod end of cylinder to oil tank).
Pressure p2 can be obtained by summing forces on the hydraulic cylinder.

p2Apiston 5 Fload or p2 5 Fload>Apiston (9-8)

Also, the extending speed of the cylinder can be represented as a function of the
flow rate through the flow control valve as follows:

ycyl 5 Qcyl>Apiston 5 QFCV>Apiston

Combining the preceding equation with Eqs. (9-7) and (9-8) yields the
final result.

pPRV 2 Fload>Apiston
Apiston B
Cv
ycyl 5 (9-9)
SG

As can be seen by Eq. (9-9), by varying the setting of the flow control valve,
and thus the value of Cv , the desired extending speed of the cylinder can be
achieved.


 Chapter 9

Meter-In Versus Meter-Out Flow

Control Valve Systems

The circuit of Figure 9-17 depicts a meter-in flow control system, in which the flow
control valve is placed in the line leading to the inlet port of the cylinder. Hence a
meter-in flow control system controls the oil flow rate into the cylinder. Conversely,
a meter-out flow control system is one in which the flow control valve is placed in
the outlet line of the hydraulic cylinder. As shown in Figure 9-18, a meter-out flow
control system controls the oil flow rate out of the cylinder.
Meter-in systems are used primarily when the external load opposes the direc-
tion of motion of the hydraulic cylinder. An example of the opposite situation is
the case of a weight pulling downward on the piston rod of a vertical cylinder. In
this case the weight would suddenly drop by pulling the piston rod down if a meter-
in system is used even if the flow control valve is completely closed. Thus, the
meter-out system is generally preferred over the meter-in type. One drawback of
a meter-out system is the possibility of excessive pressure buildup in the rod end
of the cylinder while it is extending. This is due to the magnitude of back pressure
that the flow control valve can create depending on its nearness to being fully
closed as well as the size of the external load and the piston-to-rod area ratio of
the cylinder. In addition an excessive pressure buildup in the rod end of the cylin-
der results in a large pressure drop across the flow control valve. This produces
the undesirable effect of a high heat generation rate with a resulting increase in oil
temperature.

p1

Qpump –QPRV

Fload

υcyl
p3 p2

FCV

QFCV
Qpump

QPRV

PRV

Figure 9-18. Meter-out speed control of hydraulic cylinder during extending stroke
using flow control valve. (DCV is in manually actuated position.)


Hydraulic Circuit Design and Analysis

EXAMPLE 9-4
For the meter-in system of Figure 9-17 the following data are given:

Valve capacity coefficient 5 1.0 gpm> 2psi

Cylinder piston diameter 5 2 in 1area 5 3.14 in2 2
Cylinder load 5 4000 lb
Specific gravity of oil 5 0.90
Pressure relief valve setting 5 1400 psi

Determine the cylinder speed.

Solution The units for the terms in Eq. (9-9) are

Cy 5 gpm> 2psi
Q 5 vcyl Apiston 5 gpm
pPRV 5 psi
Fload>Apiston 5 psi

Thus, from Eq. (9-9) we have

pPRV 2 Fload>Apiston
B B
1ycylApiston 2 gpm 5 Cy
1400 2 4000>3.14
5 1.0 5 11.8 gpm
SG 0.9

5 45.4 in3>s
gal 231 in3 1 min
5 11.8 3 3
min 1 gal 60 s

Solving for the cylinder speed we have

45.4 in3>s 45.4

Apiston 1in 2
ycyl 5 2
5 5 14.5 in>s
3.14

Note that the cylinder speed is directly proportional to the capacity coef-
ficient of the flow control valve. Thus, for example, if the flow control valve is
partially closed from its current position until its flow coefficient is cut in
half (reduced from 1.0 to 0.5), the cylinder speed is cut in half (reduced from
14.5 in/s to 7.25 in/s).


 Chapter 9

EXAMPLE 9-5
For the meter-out system of Figure 9-19, which uses a suspended load, deter-
mine the pressure on each pressure gage during constant speed extension of
the cylinder for
a. No load
b. 20,000-N load
The cylinder piston and rod diameters are 50 mm and 25 mm, respectively,
and the PRV setting is 10 MPa.

Solution
a. During extension (load is lowered) the flow rate to the cylinder is less
than the pump flow rate due to the operation of the flow control valve
to achieve the desired cylinder speed. The excess flow goes through the
PRV. Thus, during extension, p1 equals approximately the pressure relief
valve setting of 10 MPa (assumes negligibly small pressure drops through
the DCV and the pipeline connecting the pump to the blank end of the
cylinder). This means that the downward hydraulic force acting on the
cylinder piston equals the pressure relief valve setting of 10 MPa multi-
plied by the cylinder piston area.

10.050 m2 2 5 19,600 N
N p
F 5 10 3 106 2
3
m 4
For a constant speed cylinder, the total net force acting on the piston and rod
combination must equal zero. Thus, for no load, we have

p1Ap 5 p2 1Ap 2 Ar 2

10.0502 2 0.0252 2m2

p
19,600 N 5 p2 3
4
p2 5 13.3 MPa
Finally, p3 equals approximately zero because this location is in the return
pipeline where oil drains back to the reservoir via the directional control valve
(assumes negligibly small pressure drop through the DCV and pipeline return-
ing oil back to the reservoir).
b. For the case where the load equals 20,000 N, pressures p1 and p3 are the
same as that found for the no-load case. However, pressure p2 is found
once again by noting that the total net force acting on the piston and
rod combination must equal zero. Thus, for a load of 20,000 N, we have

19,600 N 1 20,000 N 5 p2 3 10.0502 2 0.0252 2 m2

p
4
p2 5 26.9 MPa


Hydraulic Circuit Design and Analysis

CYL PUMP PRV p

1

p
p 2
3 CYL

FCV
DCV
PUMP
FCV
LOAD
PRV

PRV

Figure 9-19. System for Example 9-5.

This example shows that the pressure in the rod end of the hydraulic cylinder
is 2.69 times greater than the PRV setting. This large pressure must be taken
into account in terms of its potential to damage system components. Also, the
large pressure drop of 26.9 MPa across the flow control valve must be taken
into account in terms of its potential to create a high heat generation rate and
thus a large increase in oil temperature.

9.14 SPEED CONTROL OF A HYDRAULIC MOTOR

Figure 9-20 shows a circuit where speed control of a hydraulic motor is accom-
plished using a pressure-compensated flow control valve.
The operation is as follows:

1. In the spring-centered position of the tandem four-way valve, the motor is

hydraulically locked.
2. When the four-way valve is actuated into the left envelope, the motor rotates
in one direction. Its speed can be varied by adjusting the setting of the throt-
tle of the flow control valve. In this way the speed can be infinitely varied as
the excess oil goes through the pressure relief valve.
3. When the four-way valve is deactivated, the motor stops suddenly and becomes
locked.


 Chapter 9

Figure 9-20. Speed control of hydraulic motor using pressure-compensated flow

control valve.

4. When the right envelope of the four-way valve is in operation, the motor turns
in the opposite direction.The pressure relief valve provides overload protection
if, for example, the motor experiences an excessive torque load.

9.15 HYDRAULIC MOTOR BRAKING SYSTEM

When using a hydraulic motor in a fluid power system, consideration should be given
to the type of loading that the motor will experience. A hydraulic motor may be
driving a machine having a large inertia. This would create a flywheel effect on the
motor, and stopping the flow of fluid to the motor would cause it to act as a pump.
In a situation such as this, the circuit should be designed to provide fluid to the
motor while it is pumping to prevent it from pulling in air. In addition, provisions
should be made for the discharge fluid from the motor to be returned to the tank
either unrestricted or through a relief valve. This would stop the motor rapidly but
without damage to the system. Figure 9-21 shows a hydraulic motor braking circuit
that possesses these desirable features for either direction of motor rotation.

9.16 HYDROSTATIC TRANSMISSION SYSTEM

Closed-Circuit Diagrams

Figures 9-20 and 9-21 are actually hydrostatic transmissions. They are called open-
circuit drives because the pump draws its fluid from a reservoir. Its output is
then directed to a hydraulic motor and discharged from the motor back into the


Hydraulic Circuit Design and Analysis

Figure 9-21. Hydraulic motor braking system.

reservoir. In a closed-circuit drive, exhaust oil from the motor is returned directly
to the pump inlet. Figure 9-22 gives a circuit of a closed-circuit drive that allows
for only one direction of motor rotation. The motor speed is varied by changing
the pump displacement. The torque capacity of the motor can be adjusted by the
pressure setting of the relief valve. Makeup oil to replenish leakage from the
closed loop flows into the low-pressure side of the circuit through a line from
the reservoir.
Many hydrostatic transmissions are reversible closed-circuit drives that use a
variable displacement reversible pump. This allows the motor to be driven in either
direction and at infinitely variable speeds depending on the position of the pump
displacement control. Figure 9-23 shows a circuit of such a system using a fixed dis-
placement hydraulic motor. Internal leakage losses are made up by a replenishing
pump, which keeps a positive pressure on the low-pressure side of the system. There
are two check and two relief valves to accommodate the two directions of flow and
motor rotation.

Track-type Tractor Application

Figure 9-24 shows a cutaway view of a track-type tractor that is driven by two closed-
circuit, reversible-direction hydrostatic transmissions. Each of the two tracks has its


 Chapter 9

ELECTRIC
MOTOR

Figure 9-22. Closed-circuit,

one-direction hydrostatic transmission.

REPLENISHING
CHECK VALVE
FIXED
DISPLACE-
REVERSIBLE MENT
PUMP REPLENISHING MOTOR
FILTER PUMP

REPLENISHING
RELIEF VALVE

OVERLOAD
RELIEF VALVE

Figure 9-23. Closed-circuit, reversible-direction hydrostatic transmission. (Courtesy

of Sperry Vickers, Sperry Rand Corp., Troy, Michigan.)

own separate hydraulic circuit. The two variable displacement piston pumps
are attached directly to the diesel engine flywheel housing. Each pump delivers
17.6 gpm (66.7 Lpm) at the rated speed of 2400 rpm and 1000 psi (6900 kPa) pres-
sure. The pressure relief valve setting is 2500 psi (17,200 kPa). The two piston motors
(which power the drive sprockets for the two tracks) are mounted inboard of
the main frame. These motors can run with either of two different volumetric


Hydraulic Circuit Design and Analysis

Figure 9-24. Track-type tractor driven by two hydrostatic transmissions.

(Courtesy of Caterpillar, Inc., Peoria, Illinois.)

displacements, as controlled by the operator, to provide two speed ranges. With a

single joystick, the operator can control speed, machine direction, and steering.
The front variable pitch and tilt blade is driven by hydraulic cylinders to pro-
vide the necessary down force, pry-out force, and blade control for maximum pro-
duction capabilities. Applications for this tractor include finish grading, back-filling
ditches, landscaping, medium land clearing, and heavy dozing.

9.17 AIR-OVER-OIL CIRCUIT

Sometimes circuits using both air and oil are used to obtain the advantages of each
medium. Figure 9-25 shows a counterbalance system, which is an air-over-oil circuit.
Compressed air flows through a filter, regulator, lubricator unit (FRL) and into a


 Chapter 9

FLOAD

FRL EXH

EXH

AIR

OIL

Figure 9-25. Air-over-oil circuit.

surge tank via a directional control valve (upper flow path configuration). Thus, the
surge tank is pressurized by compressed air. This pushes oil out the bottom of
the surge tank and to the hydraulic cylinder through a check valve and orifice
hooked in parallel. This extends the cylinder to lift a load. When the directional con-
trol valve is shifted into its lower flow path mode, the cylinder retracts at a con-
trolled rate. This happens because the variable orifice provides a controlled return
flow of oil as air leaves the surge tank and exhausts into the atmosphere via the
directional control valve. The load can be stopped at any intermediate position by
the spring-centered position of the directional control valve. This system eliminates
the need for a costly hydraulic pump and tank unit.

9.18 ANALYSIS OF HYDRAULIC SYSTEM

WITH FRICTIONAL LOSSES CONSIDERED

Example 9-6 illustrates the technique for performing the analysis of a complete
hydraulic system, taking frictional losses into account.

EXAMPLE 9-6
The system shown in Figure 9-26 contains a pump delivering high-pressure oil
to a hydraulic motor, which drives an external load via a rotating shaft. The
following data are given:


Hydraulic Circuit Design and Analysis

LOAD
p2
ELECTRIC Nmotor
MOTOR

M
p1 HYDRAULIC
Npump MOTOR

Q A pump
PUMP

Figure 9-26. System for

Example 9-6.

Pump:

hm 5 94%
hv 5 92%
VD 5 10 in3
N 5 1000 rpm
inlet pressure 5 24 psi

Hydraulic motor:

hm 5 92%
hv 5 90%
VD 5 8 in3
inlet pressure p2 required to drive load 5 500 psi
motor discharge pressure 5 5 psi

Pump discharge pipeline:

Pipe: 1-in schedule 40, 50 ft long (point 1 to point 2)
Fittings: two 90° elbows (K = 0.75 for each elbow), one check valve (K = 4.0)


 Chapter 9

Oil:

viscosity 5 125 cS
specific gravity 5 0.9

If the hydraulic motor is 20 ft above the pump, determine the

a. Pump flow rate
b. Pump discharge pressure p1
c. Input hp required to drive the pump
d. Motor speed
e. Motor output hp
f. Motor output torque
g. Overall efficiency of system

Solution
a. To determine the pump’s actual flow rate, we first calculate the pump’s
theoretical flow rate.

1VD 2 pump 3 Np 10 in3 3 1000 rpm

1QT 2 pump 5 5 5 43.3 gpm
231 231
1QA 2 pump 5 1QT 2 pump 3 1hy 2 pump 5 43.3 3 0.94 5 40.7 gpm

b. To obtain the pump discharge pressure p1 we need to calculate the fric-

tional pressure loss (p1 - p2) in the pump discharge line. Writing the
energy equation between points 1 and 2, we have

p1 y21 p2 y22
Z1 1 1 1 Hp 2 Hm 2 HL 5 Z2 1 1
g 2g g 2g

Since there is no hydraulic motor or pump between stations 1 and 2, Hm =

Hp = 0. Also, υ1 = υ2 and Z2 - Z1 = 20 ft. Also, per Figure 10-2 for 1-in sched-
ule 40 pipe, the inside diameter equals 1.040 in. We next solve for the Reynolds
number, friction factor, and head loss due to friction.
1QA 2 pump 40.7>449 ft3>s 0.0908 ft3>s
y5 5 5 5 15.4 ft>s
a
A p 1.040 2 0.00590 ft2
ftb
4 12

7740y 1ft>s2 3 D 1in2 7740 3 15.4 3 1.040

v 1cS2
NR 5 5 5 992
125


Hydraulic Circuit Design and Analysis

Since the flow is laminar, the friction factor can be found directly from the
Reynolds number.
64 64
f5 5 5 0.0645
NR 992
Also,

HL 5 f a b
LeTOT y2
where
D 2g

LeTOT 5 50 1 2 a b 1 a b
KD KD
f 90° elbow f check valve
2 3 0.75 3 1.040>12 4.0 3 1.040>12
5 50 1 1 5 50 1 2.02
0.0645 0.0645
1 5.37 5 57.39 ft

Thus,

57.39 115.42 2
HL 5 0.0645 3 3 5 157.3 ft
1.040>12 2 3 32.2
Next, we substitute into the energy equation to solve for 1p1 2 p2 2 >g.

5 1Z2 2 Z1 2 1 HL 5 20 ft 1 157.3 ft 5 177.3 ft

p1 2 p2
g

Hence,

p1 2 p2 5 177.3 ft 3 g a b 5 177.3 ft 3 0.9 3 62.4

lb lb lb
5 9960 5 69 psi
ft3 ft3 ft2
p1 5 p2 1 69 5 500 1 69 5 569 psi

pump hydraulic horsepower

1ho 2 pump
c. hp delivered to pump 5

1569 1 4 2 psi 3 40.7 gpm

5 5 15.7 hp
1714 3 0.94 3 0.92

d. To obtain the motor speed we first need to determine the motor theo-
retical flow rate

1QT 2 motor 5 1QA 2 pump 3 1hy 2 motor 5 40.7 3 0.90 5 36.6 gpm

1QT 2 motor 3 231 36.6 3 231

1VD 2 motor
Nmotor 5 5 5 1057 rpm
8


 Chapter 9

e. To obtain the motor output hp we first need to determine the motor

input hp.

1500 2 5 2psi 3 40.7 gpm

motor input hp 5 5 11.8 hp
1714

Thus,

motor output hp 5 motor input hp 3 1ho 2 motor 5 11.8 3 0.92 3 0.90 5 9.77 hp

motor output hp 3 63,000

f. motor output torque 5
Nmotor
9.77 3 63,000
5 5 582 in # lb
1057

g. The overall efficiency of the system is

1ho 2 overall 5
motor output hp 9.77
5 5 0.622 5 62.2%
pump input hp 15.7

Thus, 62.2% of the power delivered to the pump by the electric motor is
delivered to the load by the hydraulic motor.

9.19 MECHANICAL-HYDRAULIC SERVO SYSTEM

Figure 9-27 shows an automotive power-steering example of a mechanical-hydraulic

servo system (closed-loop system). Operation is as follows:

1. The input or command signal is the turning of the steering wheel.

2. This moves the valve sleeve, which ports oil to the actuator (steering cylinder).
3. The piston rod moves the wheels via the steering linkage.
4. The valve spool is attached to the linkage and thus moves with it.
5. When the valve spool has moved far enough, it cuts off oil flow to the cylin-
der. This stops the motion of this actuator.
6. Thus, mechanical feedback recenters (nulls) the valve (actually a servo valve)
to stop motion at the desired point as determined by the position of the steer-
ing wheel. Additional motion of the steering wheel is required to cause further
motion of the output wheels.

Electrohydraulic servo systems are presented in Chapter 17.


Hydraulic Circuit Design and Analysis

Figure 9-27. Automotive example of mechanical-hydraulic servo system.

9.20 KEY EQUATIONS

Regenerative cylinder QP (9-1)

yPext 5
extending speed: Ar

Regenerative cylinder QP (9-2)

yPret 5
retracting speed: AP 2 Ar

Regenerative cylinder ypext Ap (9-3)

extending to retracting 5 21
speed ratio: yPret Ar

Regenerative cylinder
extending load-carrying Fload 5 pAr (9-4)
capacity:

Total load-carrying
capacity of two cylinders
hooked in series and p1Ap1 5 F1 1 F2 (9-5)
extending in
synchronization: