.

-1
. 7/0 3/0
(. 100 bar )

-2
.
 Volume =
Volume =
99.3
100 Litres
50
251 Litres
100 Litres
Litre Litres 100
1 Bar
1004
1 Bar
2 Bar abs
absabs
abs

AIR OIL
 -1
-2

1- STATIONARY HYDRAULICS
2- MOBILE HYDRAULICS
Stationary hydraulics

The following application areas are important for stationary hydraulics:

- Production and assembly machines of all types

- Transfer lines
- Lifting and conveying devices
- Presses
- Injection moulding machines
- Rolling lines
- Lifts

Machine tool construction is a typical application area.

FESTO DIDACTIC Training & Consulting No. 1/18

Pre-fill valves presentation
Mobile hydraulics

Typical application fields for mobile hydraulics include:

- Construction machinery
- Tippers, excavators, elevating platforms
- Lifting and conveying devices
- Agricultural machinery

FESTO DIDACTIC Training & Consulting No. 1/18

Pre-fill valves presentation
-1
-2
-3
-4
-5
 -1
-2
-3
= -4
-5
 VISCOSITY
2
:
= mm / s
. : -1
. : -2
 PRESSURE

PRESSURE
is a FORCE

acting on an AREA

These 3 variables are linked by the

formula
FORCE (In Pounds, Newtons or Kg)
PRESSURE =
AREA (In square inches, metres
or cm)
 Pressure

1 kg

1 kg

LOW HIGH
PRESSURE PRESSURE
 Units of pressure

Pressure

BAR psi Pascal

1 14.7 100,000

1 Newton
1 Pascal =
1 metre 2
GAUGE
 Bourdon tube gauge

FESTO DIDACTIC Training & Consulting No. 1/51

PRESENTATION
 FLOW RATE
.

Q=V/T
Q=v.A
FLOW RATE
is a VOLUME
in a given TIME

These 3 variables are linked by the

formula
VOLUME Cubic metres, litres
FLOW RATE = or gallons
TIME Seconds, minutes or
hours
 -1
-2

1- LAMINAR FLOW
2- TURBULENT FLOW
 Laminar flow

.
 Turbulent flow

.
!
( ) -1
-2
-3
-4
-5
-6
-7
-8
-9
 Pascals Law

Force = 2400 P = F/A

Newtons = 2400 /
F
20
Piston Area = = 120 N/cm2 = 12
20 cm2 Bar

Pressure is applied in all directions and acts with

equal force on equal areas
Hydrostatic force transmission

= 10 =?
= 10 = 40
Hydrostatic pressure transmission

= 40

= 10

= 20 =?
 . -1

. -2

. -3
 DIDACTIC

: ( )
2 2
P1 1 V 1 P2 1 ( V2 )
( )( ) Z1 ( ) Z2
2 g 2 g
Z1=Z2 :
.
2 2
P1 1 V1 P 2 1 ( V2 )
( )( ) ( )
2 g 2 g
V 2 V1

P2 P1 :
 DIN / ISO 1219
5 bar

CHECK VALVE
 ?
7bar
:

14bar
?

14 7
:

7
14
14 7
 -1
-2
1- THRESHOLD
2- PIPING
SHUT-OFF VALVE
ON-0FF VALVE
.
 -1
.
(. )

-2
-1
-2
-3
FESTO DIDACTIC Training & Consulting No. 1/51
PRESENTATION
. -1
. 250 -2
. -3
Internal gear pumps
Internal gear pumps
. -1
. -2
-3
.
200 100 -4
.
. -5
vane pump
 -1
.
. -2
. -3
-4
.
. 350 -5
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
Axial piston pump
. 1000 1400
 :

-1
. -2
-3
-4
-5
-6
-7
-8
Pumps
Fixed One direction of flow.
Displacemen Constant delivery for
t constant speed

Variable One direction of flow.

Displacement Variable delivery for
constant speed

Directional of flow
reversible. Variable
delivery for constant
speed.
Hydraulic Energy
Source
(simplified
representation)
Drive units
EM Electric Motor

M Engine

Motors
Fixed One direction of
Displacemen rotation.
t Constant shaft
speed for
Either direction
constant flow of
rotation,
rate depending on
direction of flow.
Constant shaft speed for
Variable Either direction
constant of
flow rate.
Displacement rotation. Speed variable
for constant flow.
 POWER PACK
. Main valve Shut off valve
. By pass Shut off valve
 :

Gauge

. Gauge
Pressure relief valve
P

T
Pressure relief valve
P

T
Pressure relief valve
P

T
 Pressure relief valve
These have the job of influencing the
pressure in a complete hydraulic system
or in part of the system.
P

T
Pressure line
P

T
Pressure relief valve operating curve (directly actuated)
P
Full flow
pressure
Over ride
Cracking
pressure

Q
FESTO DIDACTIC Training & Consulting No. 2/51
PRESENTATION
Q

P
 Relief

Setting -
-
-
-
 P

T T -1
-2

1- PILOT OPERATED PRESSURE RELIEF VALVE WITH INTERNAL DRAIN

2- PILOT OPERATED PRESSURE RELIEF VALVE WITH EXTERNAL DRAIN

. 75 GPM
FESTO DIDACTIC Training & Consulting No. 1/18
Pre-fill valves presentation
Pilot operated pressure relief
valve
Loadi
ng
sprin
g Adjust
ing
Screw
Cont
rol
pist
on
Cont
rol
orifi
ce
Pilot operated pressure relief
valve

Pressure
builds
Pilot operated pressure relief
valve

Pressure
builds
Pilot stage
opens and
oil flows to
tank
Pilot operated pressure relief
valve

Pressure
builds
Pilot stage
opens and
oil flows to
The flow of
tank
oil through
the control
orifice
creates a
pressure
difference
across the
piston
Pilot operated pressure relief
valve

Pressure
builds
Pilot stage
opens and
oil flows to
The flow of
tank
oil through
the control
orifice
creates a
pressure
This
difference
pressure
across the
differenc
piston
e lifts
the piston
and
opens the
Pilot operated pressure relief
valve

Pressure
builds
Pilot stage
opens and
oil flows to
The flow of oil
tank
through the
control orifice
creates a
pressure
difference
This pressure
across the
difference
piston
lifts the
piston and
opens the
flow path
to tank.
Pilot operated pressure relief
valve

Pressure
reduces
and valve
resets
Pilot operated pressure relief
valve

Pressure
reduces
and valve
resets
 Pilot operated pressure relief
valve operating curve
P
Full flow
pressure
Cracking Over ride
pressure

Q
 :
. -1
-2
-3
. 5 3 -4

(. )
-1
-2
-3
-4
-5
-6
.
. 40
.

HL -1
HLP -2
HV -3
90 HFA -4
40 HFB -5
30 HFC -6
HFD -7
 Conventional hydraulic systems
Actuation

Pressure line
Direction control element
Pressure control element

Hydraulic liquid Electric motor

Tank Return line

Suction line
 ACTUATORS

LINEAR ACTUATORS -1
ROTARY ACTUATORS -2
 ( ) -1
( ) -2

1- SINGLE ACTING CYLINDER S.A.C

2- DOUBLE ACTING CYLINDER D.A.C
Single-acting cylinder

Cylinder (reset by spring)

 DOUBLE ACTING CYLINDER (D.A.C)
Double Acting Cylinder (DAC)

Extend

Retract

FESTO DIDACTIC Training & Consulting No. 1/51

PRESENTATION
SPECIAL CYLINDERS
TELESCOPIC CYLINDER
FLOAT CYLINDER
( )
RAM
 Ap Ar

(Ap Ar) = Apr

= (Ap / Apr) DIFFERENTIOAL CYLINDER

Double-acting cylinders

BALLANCE
TANDEM CYLINDER
Hydraulic cylinders
Hydraulic cylinders
 -1

-2

1- VANE TYPE
2- RACK & PINION
 .
:

-1
-2
-3
 Vane Types

FESTO DIDACTIC Training & Consulting No. 1/51

PRESENTATION
 Rack & Pinion Types

FESTO DIDACTIC Training & Consulting No. 1/51

PRESENTATION
FESTO DIDACTIC Training & Consulting No. 1/51
PRESENTATION
1- FUNCTION
2- METHOD OF ACTUATING
3- DESIGN

-1
-2
-3
 FUNCTION
1- DIRECTIONAL CONTROL VALVES
2- FLOW CONTROL VALVES
3- PRESSURE CONTROL VALVES

-1
-2
-3
 DIRECTIONAL CONTROL
VALVES

1- CHECK VALVES
2- SHUT - OFF VALVES
3- WAY VALVES
Non-return valve
Non-return valve
Non-return valve
WAY VALVES
/
 :

P -1
A,B,C -2
R,S,T -3
X,Y,Z -4
L,K -5
Directional Control
Valves A

P
Reset Valve L
spring A Body

L 2/2 way valve

P
End cap Spoo 2 ports
with seals l 2 control
Leakage positions
line push button
operation
spring return
normally
Directional Control
Valves A

P
L

L P
Directional Control
Valves A

P
L

L P
Directional Control
Valves A

P
L

L P
Directional Control
Valves A

P
L

L P
Directional Control
Valves A

P
L

L P
Directional Control
Valves A

P
L

L P
Directional Control
Valves A

P
L

L P
Pressure is
Leakage oil escapes
contained within
stopping pressure build
the spool and
up on the ends of the
the valve body,
spool
not applied to
the end caps.
Directional Control
Valves A

P T
L

L P T 3/2 way valve

Push button
operated
Spring return
Normally
closed
Directional Control
Valves A

P T
L

L P T 3/2 way valve

Push button
operated
Spring return
Normally
closed
Directional Control
Valves A

P T
L

L P T 3/2 way valve

Push button
operated
Spring return
Normally
closed
 Directional Control Valves
Spring chamber is part
of the return line to
tank. Care must be A
taken that this line is
not pressurised B
otherwise damage may
result

P
T

T A P B 4/2 way valve

Push button
operated
Spring return
Changeover
valve
Directional Control Valves
A
B

P
T

T A P B 4/2 way valve

Push button
operated
Spring return
Changeover
valve
Directional Control Valves
A
B

P
T

T A P B 4/2 way valve

Push button
operated
Spring return
Changeover
valve
Roller
operation
 THREE POSITIONS VALVES

1- 5/2 PNEUMATIC VALVES

2- 4/3 CENTER POSITIONS IS CLOSE

3- 4/3 CENTER POSITIONS IS PUMP BY PASS

4- 4/3 CENTER POSITIONS IS FLOAT (P CLOSE)

5- 4/3 CENTER POSITIONS IS OPEN

6- 4/3 CENTER POSITIONS IS BY PASS (T CLOSE)

7- 5/3 PNEUMATIC VALVES

Valves with centre positions
 DESIGN

1- POPPET DESIGN
2- SPOOL DESIGN
-1
( ) -2
POPPET DESIGN
1- BALL
2- DISK
3- CONE
-1
-2
-3
A1 A2
FESTO DIDACTIC Training & Consulting No. 1/18
Advanced hydraulics presentation
 -1
3 -2
-3

-1
-2
-3
 OVERLAP

1- POSITIVE OVER LAP

2- ZERO OVER LAP
3- NEGATIVE OVER LAP
 Piston Overlap

Positive Negative Zero

overlap overlap overlap
 Switching Overlap

A A

P T P T
50 Bar 50 Bar

50 50
8
Bar Bar
Bar
 PILOTED CHECK VALVE
DE-LOCKABLE VALVE

4/3 directional control valve with float mid position

FESTO DIDACTIC Training & Consulting No. 1/18

presentation
 De-lockable double non-return
valves

.
 Piloted non-return valve

In piloted non-return valves, flow can be released in the closed position

by pilot control of the valve poppet. This takes place according to the
following principle:
Flow is possible from A to B, flow is blocked from B to A.

Flow blocked from B to A Flow from A to B Flow from B to A

FESTO DIDACTIC Training & Consulting No. 1/18

Pre-fill valves presentation
FLOW CONTROL VALVES

1- THROTTLE

2- ORIFICE

.
THROTTLE ORIFICE
L

L d L< d
 .

P1 P2
 ONE WAY FLOW CONTROL VALVES

One-way flow control valve

Flow control valve with free flow check valve

FESTO DIDACTIC Training & Consulting No. 2/51

PRESENTATION
 METER IN

. METER IN
 METER OUT

. METER OUT
 CAVITATION
&
MICRO DIESEL
FESTO DIDACTIC Training & Consulting No. 2/51
PRESENTATION
.
. -1
. -2
( ) -3
-4
 : METER IN

1- REFERENCE
2- BRACKING
3- TRACTIVE FORCE
 .
2 Dependent on load
P Q
Flow control
Flow control

. Tractive Force
 : METER OUT

1- REFERENCE
2- BRACKING
3- TRACTIVE FORCE
 METER OUT METER IN

METER IN

(DEPENDENT ON LOAD)

METER OUT

FLOW CONTROL
.
 :

:
: B A

A=B -1
A A>B -2
A<B -3
A>B -4
B A<B -5
A>B -6
X PRESSURE COMPENSATOR VALVE

HYDROSTAT
Y
 INDEPENDENT ON LOAD
2 WAY FLOW REGULATOR VALVES
INDEPENDENT ON LOAD
FESTO DIDACTIC Training & Consulting No. 2/51
PRESENTATION
COUNTER BALLANCE VALVE
 PRESSURE CONTROL VALVES
1- PRESSURE RELIEF VALVES
( )
2- TWO WAY PRESSURE REDUCING
VALVE

3- THREE WAY PRESSURE REDUCING

VALVE
( )
EQUAL SPEED
 GRAETZ

.
 :