Fluid System Circuits

1
Fluid circuits
• Group of hydraulic and pneumatic components 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

2
Control of single acting cylinder
• DCV position 1: Fluid from source fills into
piston side of cylinder. The piston extends
against spring.

• DCV position 2: The spring pushes back the

piston, so the fluid on piston side drains to the
tank.

• NB: Incase of pneumatic system the air not

returned to tank instead it released to the
atmosphere.

3
Control of double acting cylinder
• DCV position 1: Fluid from source fills into
piston side of cylinder. The piston extends.

• DCV position 2: Fluid from source pushes

back the piston from rod side, so the fluid on
piston side drains to the tank.

• NB: Incase of pneumatic system the air not

returned to tank instead it released to the
atmosphere.

4
Regenerative circuit
• Used to increase extending speed of the piston by
diverting the fluid flow from rod side into piston side
during extension stroke.

• Q=Av [Flow rate=area*velocity]

• In normal use the extension speed is generated by

Qp-pump flow rate, incase of regenerative the speed
is the sum of Qp-pump flow rate and Qr-cylinder rod
side flow rate.

5
Pump-Unloading circuit
• The pump is not working with maximum horsepower
so unloading valve is acting only depending on the
pressure developed as a cylinder is fully extended or
retracted.

• As the cylinder fully extended or retracted pressure

starts to develop so, the unloading valve will be
activated and the pump flow diverted to the tank
through unloading valve.

6
Double pump circuit
• Some applications require high speed (rapid extension

of piston) and high pressure (metal punching), this

requires pump with high pressure and high flow rate

which is expensive.

• In this case two pumps with high pressure-low flow

rate and low pressure-high flow rate can be used.

• The system uses the low pressure-high flow rate for

extension and high pressure-low flow rate for

punching purpose.
7
Counter balance circuit
• Prevents a vertical cylinder from being descended by gravitational force.

• During retraction (i.e. moving the load upward) the fluid flows through
check valve.

• Since the cylinder arranged vertically and gravity is acting downward the
weight can be descended with out pressure on piston side. To prevent
this CBV is used and its pressure is adjusted to the value that can hold
the weight.

• If more pressure is applied on piston side it can safely descended down.

8
Sequencing circuits
• The cylinders needs to be activated one after the
other.

• As cylinder 1 is fully extended pressure starts to

develop. When this pressure reaches at the setting of
PRV2, cylinder 2 starts to extend.

• In retraction stroke, as cylinder 2 is fully retracted

pressure starts to develop. When this pressure reaches
at the setting of PRV1, cylinder 1 starts to retract.

9
Reciprocating Circuit
• The cylinder is reciprocating between full extension
and retraction automatically.

• After full extension pressure develops in piston side so

pilot pressure activates the valve to retraction
position.

• As cylinder fully retracted pressure start to develop in

rod side. So, pilot pressure activates the valve to
extension position.

10
Cylinder Synchronization
Parallel Series

The cylinders can not be effectively synchronized. In case of series synchronization the cylinders can be
This is because even if the flow rate and areas of effectively synchronized the major requirement is
both cylinders are equal factors like force/load and making area of rod side cylinder 1 equal with piston
packing friction may vary. side area of cylinder 2.

11
Fail safe circuits: Protection from un-intentional Cylinder Extension
• Fail-safe circuits are designed for preventing
injury to operator and equipment damage.

• In this circuit the cylinder extends if

• The pump is running and pilot actuated valve is

activated

• The push button actuated valve is activated

• The cylinder will not extend if the pipe is raptured

unless it is between check valve and cylinder.

12
Fail safe circuits: Overload Protection
• Overload protection circuits used for preventing
rapture of pipes and failure of devices caused by over
pressure.

• If valve 2 is activated it activates valve 1 with pilot so,

fluid enters on piston side to extend the cylinder,
even if pilot actuated check valve activated the
pressure may rise and cause failure of pipe and device
to reduce the pressure valve 3 actuated through
sequence valve so, the fluid discharged to tank.

13
Fail safe circuits: Two-hand safety
• Some systems may require higher accuracy and safety. In such
cases two operators or hands of actuation require for safety cases.

• If only the first pb pressed the dcv will not actuated dcv because
the fluid will choose less resistant way which is tank through pb 2.

• If only the second pb pressed the dcv will not actuated because
the fluid will choose less resistant way which is tank through pb 1.

• To extend the cylinder both pbs should be activated at the same

time.

14
Speed control: meter in
• The speed control is attained by controlling the flow
rate of the fluid.

• Incase of meter in FCV the flow rate to the cylinder

is controlled.

• Used primarily when the external load opposes the

direction of motion of the cylinder.

15
Speed control: meter out
• Speed is controlled by controlling the flow out of the
cylinder.

• Used incase of weight pulling downward on the

piston rod of a vertical cylinder.

• Drawback of a meter-out system is the possibility of

excessive pressure buildup in the rod end of the
cylinder while it is extending.

16
Speed control: Hydraulic motor
• A pressure compensated FCV is used before DCV for
regulating the flow to a hydraulic motor, so we can
control the speed of the hydraulic motor.

• DCV position 1, the motor rotates clockwise.

• DCV position 2, locked position the motor stops.

• DCV position 3, the motor rotates counter clockwise

direction.

17
Hydraulic motor braking/ decelerating system

• A hydraulic motor driving a machine having a large inertia

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.

• Brake circuit provides fluid to the motor while it is pumping

to prevent it from pulling in air and a way for the discharged

fluid from the motor to be returned to the tank

• This would stop the motor rapidly but without damage to the

system.

18
Hydrostatic transmission
• It is a hydraulic system where the hydraulic pump or an accumulator
will drive the motor using the fluid passing through flexible hoses.
• Closed-circuit drive: unlike open-circuit the motor output fluid fed
into pump. Incase of open-circuit the fluid from motor output flows
back into tank.
• One direction closed-circuit drive: Motor speed varied by changing
the pump displacement. Torque capacity adjusted by the pressure
setting of the relief valve.
• Two direction closed-circuit drive: Uses variable displacement
reversible pump. Speed and direction of the motor controlled by
varying speed and direction of the pump.
19