Hydraulic Circuit Design & Analysis

Design Considerations

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

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.

Meet functional requirements Meet required performance Fluid transport systems designed to specification delivery of a fluid from one location to Life expectancy same as machine another to accomplish some useful Facilitate good maintenance practice purpose. Compatibility with electrical and Fluid Power systems designed to mechanical components perform work. Withstand operational hazards
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Linear Circuits

Simple reciprocating circuit

Circuit Design Problem

In a sheet metal forming press. The shape to be formed is hemispherical cup of radius 15 cm in 2 mm thick mild steel sheet. The force required to deform sheet is 8 kN. The forming hammer should approach job from a distance of 30 cm. The production rate required is 240 components/hr. Calculate and suggest the following specifications of the various hydraulic components used:

Reservoir Strainer Pump Flexible coupling Electric Motor Connectors Relief valve DCV 4 way Hyd. Cylinder

Hydraulic Cylinder (bore & length) Pump pressure and flow rate Electric motor HP considering 75% pump efficiency Reservoir size Size of pump inlet and discharge tubing

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

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 What Size reservoir should be used? 2.5-3.0 times the pump capacity (l/min) 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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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

Control of a Single Acting Hydraulic Cylinder

Control of a Double Acting Hydraulic Cylinder

Two Position Three Way Manually Actuated Spring Offset DCV

Three Position Four Way Manually Actuated Spring Centered DCV