Design of hydraulic

cylinder

Acknowledgement
This project consumed huge amount of work, research and
dedication. Still, implementation would not have been
possible if we did not have a support of many individuals and
organizations. Therefore we would like to extend our sincere
gratitude to, Dr. Wang Chenglong.

Kulasekara Arachchige Sajith Sameera

1201042004

Contents
About hydraulic cylinders
Operation of a Hydraulic Cylinder
Types of hydraulic cylinders
Cylinder Construction
Types of mounting
Calculations
Hydraulic circuit diagram
Figures of the pro engineering design
References

Kulasekara Arachchige Sajith Sameera

1201042004

 INTRODUCTION
Cylinders are used to convert fluid power into mechanical motion. Hydraulic
cylinders are used at high pressures and produce large forces and precise
movement. For this reason they are constructed of strong materials such as steel
and designed to withstand large forces. A cylinder consists of a cylindrical
body, closures at each end, movable piston, and a rod attached to the piston.

How hydraulic Cylinders Work

An hydraulic cylinder operates through pressurized fluid (usually oil), which
gives the hydraulic cylinder force. The cylinder's driving force is the piston,
which is attached to a piston rod that is enclosed in the cylinder's barrel. The
bottom of the barrel is closed off by the cylinder cap and the top is closed off by
the head. The head contains a round hole, which allows the piston rod to come
out of the barrel. The inside of the barrel contains the oil, and the hydraulic
pressure that the oil creates acts on the piston rod, causing it to move back and
forth in a linear fashion. One end of the piston is attached to the object or
machine it is responsible for moving. As the hydraulic pressure of the oil moves
the piston rod, the piston rod moves the piston, which in turn moves the
attached object.

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1201042004

 HYDRAULIC CYLINDERS
Cylinder Types --- Standard cylinders have been designed to meet the wide
range of applications. The following types of cylinders provide an overview of
what is available.
SINGLE-ACTING CYLINDER
The single-acting cylinder is pressurized at one end only, with the opposite end
vented to atmosphere through a breather filter (air cylinder) or vented to a
reservoir (hydraulic cylinder).The return stroke of the cylinder is accomplished
by some external means.

DOUBLE-ACTING CYLINDER
The most familiar double acting cylinder is the single rod end. This type of
cylinder provides power in both directions, with a pressure port at either end.
Single rod end cylinders exert greater forces when extending than when
retracting, since the piston area on the blind end is larger than the piston area on
the rod end (due to the area covered by the piston rod).

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1201042004

 POSITIONAL OR DUPLEX CYLINDER

Duplex cylinders are similar to tandem cylinders in that both are cylinders
connected in line, but the pistons of a duplex cylinder are not physically
connected; the rod of one cylinder protrudes into the non-rod end of the second,
and so forth. A duplex cylinder may be more than two in-line cylinders and the
stroke lengths of the individual cylinders may vary. These results in a
component that can achieve a number of different fixed stroke lengths
depending on which of the cylinders and on which end the cylinders are
pressurized.

SPRING RETURN CYLINDER

The spring return cylinder is normally considered a single acting cylinder. The
operation of this type of cylinder is the same as a single acting cylinder, except
that a spring is used to accomplish the return stroke.

DOUBLE ROD END CYLINDER

The double rod end cylinder is used when it is necessary for the cylinder to
exert equal force and operate at equal speed in both directions. It also can be
used to operate limit valves or switches.

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1201042004

 TANDEM CYLINDER
A tandem cylinder consists of two cylinders mounted in line with the pistons,
connected by a common piston rod. The main advantage of this cylinder is the
multiplication of force, during the entire stroke, without requiring higher
operating pressures or larger bores.

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1201042004

 CYLINDER CONSTRUCTION
l-cap 2-stirrup 3,5,9,11-seals 4-piston 6-barrel 7-rod end 8-bush 10-cover

Hydraulic cylinders are categorized as ram, single-acting and double

acting.
A ram cylinder has the simplest design of all hydraulic cylinders because
it has only one chamber and provides force in only one direction.
Most single-acting cylinders have a rod end vent that allows air to enter
and vent from the rod end of the cylinder.
A single acting, spring return cylinder uses fluid flow for extension and a
spring for retraction.
A telescoping ram cylinder is a hydraulic cylinder that extends its rod in
stages.
Double-acting cylinders are able to produce force in both directions by
applying hydraulic fluid pressure to either side of the piston.
A double-rod cylinder can provide equal force and piston speed in both
directions.
Tandem cylinders consist of two or more in-line cylinder barrels with
their rods connected to form a common rod.
A cushion is a tapered plug attached to the piston and rod and includes a
needle valve with a check valve in the end cap at the rod end, cap end, or
both.
Cylinder mounting methods are categorized as fixed or pivot.

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1201042004

 Types of mounting

Flange mounting
Foot mounting
Clevis mounting
Tunnion mounting

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1201042004

 CALCULATION FOR CYLINDER

Given values
Force --- 5000KN
Power --- 18MPa
The inner diameter of the cylinder tube

The diameter of the piston rod

d= 0.7D
d= 0.7 x 600 mm
d= 420 mm
Longest stroke of the cylinders as L
(From the table let assume L as)
L= 500mm

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1201042004

 The shortest guide Length H

The length of the guide sleeve sliding surface

(

The length of the guide sleeve sliding surface A

(

Cover thickness

)
)

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1201042004

 length of the cylinder tube

Lc = L+B+2t
Lc= 500+360+(2x 123.23)
Lc= 1106.46mm
Wall thickness of the cylinder tube
[(

)
)

The diameter of the cylinder tube

The width of the spacing sleeve

(
(

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)
)

1201042004

A - Length of the guide sleeve sliding surface

B - Piston width
C - The width of the spacing sleeve
D inner diameter of the cylinder tube
d the diameter of the piston rod
H The shortest guide length
K extra guiding spacing sleeve
L longest stroke of the cylinder

Kulasekara Arachchige Sajith Sameera

1201042004

 Hydraulic circuit diagram

DPC Double acting cylinder. ( This definition above)

PCV Pilot operated check valve.

HYDAC Pilot operated check valves for oil-hydraulic systems, on which the
shut-off function can be cancelled hydraulically. Due to the seat valve
construction, the valve is leaking free in the shut-off position.
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1201042004

 DCV 4/3 way tandem type push pull button with spring return

Application of 4/3 DCV (closed neutral) for controlling a doubleacting cylinder.

The valve shown here is spring centered, which means that it always returns
to the neutral position automatically when not actuated. For closed neutral,
the pump line is blocked so that the flow must pass over the pressure relief
valve the pressure is at the system maximum. This is wasteful thing because
it generates power in the form of pressure and flow, but does not use it. The
wasted energy in the system goes as heat. This is undesirable because the
hydraulic fluid becomes thinner (less viscous) as it heats up. When the fluid
becomes -50 LPM 40 LPM 13 bar 11 bar it does not lubricate effectively.
This is the result of increased wear. The outlet lines to the cylinder are
blocked, so the cylinder is held trimly in position. This is because the lines
are full of hydraulic fluid that is incompressible. This type of neutral could
also be used to control a motor. Just like cylinder, the motor is held tired in
position when the valve is in the neutral.
Application of 4/3 DCV (tandem neutral) for controlling a doubleacting cylinder.
The pump flow is allowed to flow back to the tank through the DCV when it
is in the neutral. This is a very desirable situation because only pressure in
the pump line is due to the flow resistance of the lines and DCV. This keeps
the pressure low when the valve is in the neutral. In this situation, the system
is said to be unloaded because the power consumption is reduced. This
wastes much less energy than does a closed central neutral that forces the
fluid over the pressure relief valve at a high pressure. The cylinder is held in
position with a tandem neutral because the outlet port is blocked.
PRV- Pressure relief valves.
The relief valve (RV) is a type of valve used to control or limit the pressure
in a system or vessel which can build up for a process upset, instrument or
equipment failure, or fire. The pressure is relieved by allowing the
pressurized fluid to flow from an auxiliary passage out of the system.

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1201042004

 FDP Fixed displacement pump.

A hydraulic pump is a mechanical device that converts mechanical power
into hydraulic energy. It generates flow with enough power to overcome
pressure induced by the load. The Fixed-Displacement Pump block
represents a positive, fixed-displacement pump of any type as a data-sheetbased model. The key parameters required for this block are pump
displacement, volumetric and total efficiencies, nominal pressure, and
angular velocity. All these parameters are generally provided in the data
sheets or catalog.

AR Atmospheric reservoir.

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1201042004

 Figures of the pro engineering design

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1201042004

References
Internet
Text book
Information from my seniors

Kulasekara Arachchige Sajith Sameera

1201042004

Kulasekara Arachchige Sajith Sameera

1201042004