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Hydraulic Circuit

Design & Analysis


Dr. Sunil Jha

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Design Considerations
„ Safety of Operation
… Pressure and Temperature ratings
… Interlocks for sequential operations
… Emergency shutdown features
… Power failure locks
… Operation speed
… Environment conditions

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Design Considerations
„ Meet functional requirements
… Meet required performance specification
… Life expectancy same as machine
… Facilitate good maintenance practice
… Compatibility with electrical and mechanical
components
… Withstand operational hazards

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Design Considerations
„ Efficiency of Operation
… Keep system Simple, Safe and Functional
… Access to parts need repair or adjustment
… Design to keep min operational cost
… Design to prevent and remove contamination.

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Linear Circuits
„ Simple reciprocating circuit
• Reservoir
• Strainer
• Pump
• Flexible coupling
• Electric Motor
• Connectors
• Relief valve
• DCV – 4 way
• Hyd. Cylinder

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Circuit Design Approach


„ What are the specifications of the job?
… Force requirement – 8 kN
… Length of work stroke – 15 cm
… Speed of piston and rod assembly – 0.5 sec

„ What Size of Cylinder is needed?


… Force known. Cylinder Area & Operating
Pressure must be selected. F = PA
… Standard bore and rod size cylinders

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Circuit Design Approach
„ Cylinder Selection Reasoning
… Large Diameter Cylinder
„ Operates at Low Pressure

„ Requires Bigger pump for speed

… Small Diameter Cylinder


„ Operates at High Pressure

„ Smaller pump give speed

„ Cylinder selected = 50 mm bore


„ Find Pressure and then select suitable pump

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Circuit Design Approach


„ What Capacity Pump is needed?
… Max Cylinder Speed required
… Flow rate = (Cyl Area)x(Stroke)/(time)
… Pump selection

„ What size of Electric Motor needed?


… Calculate power required to run Pump
… Consider efficiency of pump
… Shaft size, type and electric source
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Circuit Design Approach
„ What Size reservoir should be used?
… 2.5-3.0 times the pump capacity
„ What size of Electric Motor needed?
… Calculate power required to run Pump
… Consider efficiency of pump
… Shaft size, type and electric source

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Circuit Design Approach


„ Size of pump inlet?
… Inlet flow velocity = 60-150 cm/sec
„ Size of Discharge tubing?
… Outlet flow velocity = 200 – 450 cm/sec
„ Relief valve selection
… Pressure range
… Valve port size
„ Direction Control valve
… Based on function
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Control of a Single Acting Hydraulic
Cylinder

Two Position
Three Way
Manually Actuated
Spring Offset
DCV

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Control of a Double Acting


Hydraulic Cylinder

Three Position
Four Way
Manually Actuated
Spring Centered
DCV

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Regenerative Circuit
Qt

„ Pressurized fluid
discharge returned
to system
„ Speed up
Extend Retract Qr
extending speed
„ Retraction bypass Qp
DCV

Qt = Qp + Qr

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Drilling Machine Application


„ Spring centered
position – Rapid
spindle advance

„ Left envelope –
Slow feed

„ Right envelope –
Retracts piston

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PUMP Unloading circuit
„ Unloading valve
unloads the pump
at the ends of
extending and
retracting strokes
„ As well as in
spring centered
position of DCV

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Double Pump Hydraulic System


„ Punch Press
„ Initial Low
Pressure high
flow rate req.
Relief
„ When punching Valve
operation begins,
increased
pressure opens
Unload
unloading valve Valve
to unload low
pressure pump.

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Counterbalance Valve
„ To keep vertically
mounted cylinder in
upward position while
pump is idling.
„ Counterbalance
valve is set to open
at slightly above the
pressure required to
hold the piston up.

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Hydraulic Cylinder Sequence


Circuit
„ Left Env: Left Cyl
extends completely
and then Right Cyl
extend.
„ Right Env: Right Cyl
retracts fully and
then Left Cyl
retracts.

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Automatic Cylinder Reciprocating
System
„ Two sequence
valve sensing
strokes completion
by corresponding
pressure build up.

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Locked Cylinder using Pilot Check


Valves
„ Lock Cylinder so that
piston can not move
by external load.

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Cylinder Synchronizing Circuit

„ Cylinders connected in parallel


„ Loads identical – Moves in exact synchronization
„ Loads Not exactly Identical (practical situation)
„ Cylinders also not exactly identical (packing Friction)

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Cylinder Synchronizing Circuit

„ Cylinders connected in Series


„ For two cylinder to be synchronized
„ Piston Area of Cyl 2 = Piston Area of Cyl 1-
Rod area
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Cylinder Synchronizing Circuit

„ Pump pressure should overcome load


acting on both cylinders.
P1Ap1- P2(Ap1-Ar1) = F1
P2Ap2- P3(Ap2-Ar2) = F2
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Cylinder Synchronizing Circuit


Q. For the Cylinder Synchronizing Circuit, what pump
pressure is required if the cylinder loads are 22kN
each and cylinder 1 has a piston area of 65 cm2?

Ap2 = Ap1-Ar1
P3 = 0
P1Ap1 = F1+F2

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Fail Safe Circuit
„ Designed to prevent injury to operator or
damage to equipment.
„ Prevent Cylinder from
accidentally falling on an
Operator in the event of:
… Hydraulic line ruptures
… Person inadvertently operates
manual override on Pilot
actuated DCV when pump not
operating

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Fail Safe Circuit with Overload


Protection
„ DCV-1 controlled by Push button
valve-2.
„ When Overload Valve -3 is in
spring offset mode, it drains the
pilot line of valve 1.
„ If Cyl experience excessive
resistance, Valve-4 actuates
overload valve -3. This drains
pilot line of Valve1, causing it to
return to spring offset mode.
„ Nothing happen if push button 2
pressed unless overload valve
shifted manually into blocked
configuration.

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Two hand Safety Circuit
„ Designed to protect
an operator from
injury.
„ For circuit to
function, operator
must depress both
manually actuated
valves.
„ Any one button
prevents operation.

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Speed Control of a Hydraulic Motor

„ Hydraulic Motor – Rotary Motion


„ Spring Center Position
… Motor hydraulically locked
„ Left Envelop
… Rotates Clockwise
„ Right Envelop
… Rotates Anticlockwise

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Speed Control of a Hydraulic Motor

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Hydraulic Motor Braking System


„ Hydraulic motor may be driving Machine having
a large inertia.
„ Creates Flywheel effect.
„ Stopping motor, acts as a pump.
„ Circuit is designed to provide fluid to the motor
while it is pumping.
„ Provisions should be made for discharge fluid
from motor to be returned to Tank.
„ This would stop motor without damaging.

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Hydraulic Motor Braking System

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Hydrostatic Transmission
„ Open Circuit Drives
… Pump draws fluid from reservoir
… Pump output directed to Hydraulic Motor
… Discharge from Motor into reservoir

„ Closed Circuit Drive


… Exhaust oil from the motor returned directly to
pump inlet.

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Closed Circuit One-Direction
Hydrostatic Transmission
„ Closed Circuit that
allows only one direction
of motor rotation.
„ Motor speed varied by
changing pump
displacement.
„ Torque capacity of motor
adjusted by pressure
setting of the relief valve.

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Closed Circuit Reversible Direction


Hydrostatic Transmission

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