Design And Analysis of

Hydraulic Circuits
 Introduction
A Hydraulic circuit is a group of components such as pumps, actuators, and
control valves so arranged that they will perform a useful task.
When analyzing or designing a hydraulic circuit, the following three
important considerations must be taken into account
• Safety of operation
• Performance of desired function
• Efficiency of operation
 Safety Of Operation
• Pressure and Temperature rating
• Interlocks for sequential operations
• Emergency shutdown features
• Power failure locks
• Operation speed
• Environment conditions
 Meet Functional Requirement
• Meet required performance specification
• Life expectancy same as machine
• Facilitate good maintenance practice
• Compatibility with electrical and mechanical components
• Withstand operational hazards
 Efficiency of Operation
• Keep system simple, safe and functional
• Access to parts need to repair or adjustment
• Design to keep minimum operational cost
• Design to prevent and remove contamination
 Hydraulic Circuit Elements
Each design much have following section-
• Power supply section – Pump, Electrical motor, Engine, etc.
• Power control section – Valve, Magnetic valve, PLC, Controller, etc.
• Drive Section – Cylinders, Motors
 Circuit Design Approach
The specifications of the job
• Force requirement - 8kN
• Length of work stroke - 15 cm
• Speed of piston and rod assembly is 0.5
sec
What size of cylinder needed?
• Cylinder area and operating
pressure must be selected (F =
PA)
• Standard bore and rode size
cylinders
Cylinder Selection Reasoning
• Large Diameter Cylinder – Operates at low pressure and requires bigger
pump for speed
• Small Diameter Cylinder – Operates at high pressure and requires smaller
pump for speed
Cylinder Selected – 50 mm bore
Find pressure and then select suitable pump
What capacity Pump is needed?
• Maximum cylinder speed required
• Capacity = Area of cylinder * Speed
of movement
What size of Electric Motor is needed?
• Calculate power required to run pump
• Consider efficiency of pump
What size of reservoir should be used?
• 2.5 to 3.0 times the pump capacity
Size of pump inlet?
• Inlet flow velocity = 60 – 150 cm/sec
Size of Discharging tube?
• Outlet flow velocity = 200 – 450
cm/sec
 Customer’s Requirement
For what application?
• Special purpose of drilling
Nature of the work? ( lift/clamp/push etc )
• Clamping cylinder acting first, followed by drilling
How many cylinders are required?
• Two double acting cylinders ( 1 for clamping and 1 for drilling )
 Specific details from Customers
• Bore size of cylinder (clamping – 80 mm, drilling – 63 mm)
• Rod size of cylinder is Standard
• Stroke length (clamping – 20 mm, drilling – 120 mm)
• Speed of movement (clamping – 1.5 m/min, drilling – 200 mm/min)
• Expected load (clamping – 600 kg, drilling – 500 kg)
 Calculations

Step 1 – Pump Capacity

•Capacity(cm3/min) = Area of cylinder(cm2) * Speed of movement(cm/min)
•Clamping = π/4 d1(cm2), d1 = 8 cm = 50.24 cm2
•Pump required = 50.24 cm2 * 150 cm/min = 7536 cm3
(1000 cc = 1 litre)
•Select pump capacity as 7.5 lit/min
Step 2 - Working Pressure
Pressure = Force * Area
Clamping pressure = Clamping force(kg)/Clamping area(cm2)
= 600/50.24 = 11.94 kg/cm2
Drilling pressure = 500 kg/31.15 = 16.05 kg/cm2
The maximum working pressure found out is 16.05 kg/cm2.
Step 3 – Horsepower
Power(kW) = PQ/600
P = working pressure(kg/cm2), Q = flowrate(lit/min)
Power in kW = 16.06*7.5/600 = 0.2kW = 0.26hp (1kW = 1.341hp)
Therefore we can choose the next standard size of electric motor, i.e. 0.5hp
which run at 1440 rpm.
Step 4 – Reservoir size
According to thumb rule reservoir size should be 4 times of flow rate of the
pump.
Here, pump flow rate is 7.5lit/min, therefore reservoir should be at least 30
litres.
Manufacturers standard size is 50,75,100,125 litres etc. So, 50 litres
reservoir can be chosen.
Control of single acting Hydraulic Cylinder

• Components – Single acting cylinder, 3/2 way valve, pressure relief valve,
hydraulic pump
• In the initial position fluid flow goes to the tank via PRV and piston oil
from the blank end drains back into the tank
• When actuated fluid goes to the blank end and extends the cylinder.
 Control of double acting Hydraulic
Cylinder
• Components – Double acting cylinder, 4/3 way valve
• Centered position – Cylinder is hydraulically locked and fluid from pump
goes to tank
• Left position – Cylinder is extended against the load force, Oil in the rod-
end flow back to tank via 4/3 way valve
• Right position – Cylinder retracts as oil flows into rod-end side, Oil in
blank end return to tank