HEAVY MOVABLE STRUCTURES, INC.

FOURTEENTH BIENNIAL SYMPOSIUM

October 22 – 25, 2012

PROGRESSIVE CUSHIONING FOR

HYDRAULIC CYLINDERS
Michael Hanley
Electro Hydraulic Machinery Co.
www.ehmcompany.com

CARIBE ROYALE HOTEL

ORLANDO, FLORIDA
 Hydraulic System for Spillway Gate Hoist Rehabilitation

Introduction
You may be asking “What is a hydraulic cylinder cushion and why do I need one?” The answer is
surprisingly simple and yet important to the safety of all heavy moving structures. Hydraulic cylinder
cushions have been an inexpensive option available on pneumatic and hydraulic cylinders for over 100
years. It gets down to a simple additionally machined piece attached to the cylinder rod that has the ability
to decelerate a cylinders’ velocity during the last few inches of stroke. This deceleration process is
automatic, adjustable, and requires no maintenances. It’s an elegant solution that is very cost effective if
properly executed.

To answer why you need one you first must have a very large and heavy moving structure like a flood
gate, navigational lock gate, or movable bridge span that is powered by a hydraulic system. For
mechanically operated heavy moving structures there are other hydraulic cushioning devices that
accomplishing the same objective. They are called hydraulic shock absorbers and are not part of the
discussions in this paper.

So if you have or are designing such a system the obvious need to decelerate and stop the structure from
moving at each end of the cycle can be accomplished in many ways. Gradually reducing hydraulic fluid
flow near the end of stroke is achieved with various valving schemes but they all rely on some form of
electrical control system or limit switch to initiate and control the deceleration process. The problem is
sometimes limit switches and control systems fail to operate. There’s little need to explain the effects of
what happens when a heavy structure fails to decelerate and slams into its abutment. The resultant
damage can be anywhere from mildly annoying to catastrophic.

Why not just specify a standard cylinder cushion option and be done with it? Most cylinder
manufacturers’ standard cushion option does not provide progressive deceleration and can be inadequate
for properly stopping a runaway heavy moving structure. This paper provides details for a multistage
cushioning design that provides progressively adjustable deceleration. The structure can be intentionally
driven to the end of its cycle without any need for control valve deceleration. It doesn’t eliminate the need
for control valving but provides an extra measure of safety protection from ever slamming the structure
into a hard stop at either end of its cycle.

Hydraulic Cylinder Progressive Cushions

Concept

Standard hydraulic cylinder cushioning options have been utilized for many years. The basic concept is a
simple restriction of flow exiting the cylinder during the last inch or so of stroke at either end. A spear is
added to the cylinder rod that makes contact with a closely fitted hole in the head of the cylinder. The
exiting fluid is now forced through a smaller hole fitted with an adjustable needle valve that regulates the
reduced rod velocity until the cylinder bottoms out of stroke. Increased pressure caused by the restriction
of the exiting fluid is the mechanism for slowing the load (see Figure 1 below). A check valve is installed
opposite this needle valve for return in the opposite direction so incoming fluid can be seen on the full
area of the piston. The shortcoming of standard cushions for heavy civil projects is the short length of the
cushion spear and the use of a “one size fits all” adjustable needle valve. Often times these needle valves
are sized for a much larger flow and are not able to be properly adjusted. These subjects are investigated
in greater detail below.

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 Hydraulic System for Spillway Gate Hoist Rehabilitation

Figure 1

The progressive design expands on standard cushion options using longer cushion spears and multiple
needle valves arranged in a manner that gradually reduces the number of available needle valves in the
return fluid flow path (see Figure 2). Arranging the needle valves in this way allows you to program the
deceleration profile to fit a particular application. Final tweaking different parts of the program profile are
possible in ultimately small increments via individual needle valves.

Figure 2

Designing Progressive Cushions

There are several key aspects of designing progressive hydraulic cylinder cushions to achieve maximum
results.

o Length of the cushion Spear

o Calculating the load to be decelerated
o Sizing needle valves for optimum flow control

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 Hydraulic System for Spillway Gate Hoist Rehabilitation

Cushion Spear Length

Cushion spear length is important because most civil engineering applications require cylinders to have
reserve stroke such that the structure being powered comes to its resting position prior to the cylinder
bottoming out. It’s important during installation to share the reserve stroke between each end of cylinder.
Setting of cylinders too shallow could result in the cylinder bottoming out before the span has closed and
conversely robbing the other end from the effects of the cushions. Where more than one cylinder is
involved it’s important to set them all at the same level so the cushions in all cylinders actuate in unison.
Figure 3 shows how reserve stroke is shared between both ends of the cylinder to maximize the amount of
available cushioning.

Figure 3

Reserve stroke must be taken into account when determining cushion spear length. This unused stroke is
no longer available for cushioning and must be deducted from calculations. It is possible to specify
reserve strokes as low as ½” - ¾”. Greater lengths should only be considered if there could be need for
adjustment to the point where the structure might rest.

Selecting cushion length should be approximately the same as the start point of deceleration under normal
operation. A good design will have the cushion spear making contact shortly after the normal deceleration
point such that no unintended back pressure from the cushioning operation is seen under normal
operation. When normal cylinder deceleration is taking place, fluid flow exiting the cushion circuit is less
than the needle valve setting. The cushion function is always in the background and only comes into play
when required by a runaway load causing the exiting flow to be greater than normal conditions.

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 Hydraulic System for Spillway Gate Hoist Rehabilitation

Figure 4

Generally speaking, most heavy civil engineering applications will see adequate protection with cushion
spears approximately 4-6 inches in length. Remember that reserve stroke is not usable for cushioning. So
a reserve stroke of ½” would require a 4.5” cushion spear.

The first ½” - ¾” of the spear is usually slightly tapered. This tapering insures the centering of the spear
in the accepting return line passage but it also serves an important role in initializing deceleration. The
most dramatic change in cylinder velocity happens within this first ¾” of spear engagement as available
path for exiting hydraulic fluid goes from 100% to 20% within the first ¾” of spear engagement. It’s easy
to see how flow exiting the cylinder is basically unrestricted until the tapered part of the spear starts
closing off the fluid exit path.

The area changes rapidly until the exit passage is blocked and all fluid is directed through the needle
valves. After another inch of travel the first needle valves exit path has been closed off and the final creep
speed is set by the second needle valve. The deceleration velocity profile can be changed such that more
or less change can be seen in the first needle valve prior to the final creep speed setting of the second
needle valve.

Longer cushion spears can accommodate multiple needle valves. A 6 inch spear with ¾” reserve stroke
could have as many as four needle valves. A general rule to space one needle valve per inch of available
cushion spear travel has been effective. With ¾” reserve stroke and ¾” spear taper there would only be
4.5” of travel available for a 6 inch spear.

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 Hydraulic System for Spillway Gate Hoist Rehabilitation

Calculating Load

Determining the maximum load to be decelerated in a runaway condition may be easier than you think. In
the previously mentioned condition of a heavy moving structure that’s not stopping due to a limit switch
failure it’s not the structures’ moving mass that’s as important as the hydraulic system horsepower.
Runaway conditions caused by moving water, wind, or ice are handled by the normal hydraulic system up
to the point of failure of the counterbalance, relief valves, and basic pressure vessel integrity of the
hydraulic system as a whole. Assuming these factors are taken account in initial system design, these
types of failures are not part of the cushion discussion.

The inertia and mass of the structure are certainly important to overall calculations but are typically only
10-20 percent of the load seen on the cylinder cushions in the scenario where the control system fails to
slow down hydraulic fluid flow exiting the cylinders. Most hydraulic systems are designed to output
maximum flow until the system pressure causes the variable volume pumps to de-stroke or compensate to
a lower flow. When the control system fails to regulate pump flow, the cylinder will not start to decelerate
until the backpressure from the opposite side of the piston exerts a force great enough to cause the
hydraulic pumps to compensate and reduce flow. Power from the hydraulic pumping system is a much
greater force to deal with than load from the moving structure.

Calculating the back pressure required to compensate the pumps is a simple equation based on the
available area of the piston. Keep in mind that piston area is now smaller due to the cushion spear. Figure
4 below shows a simplified version of this calculation. Basic fluid power principals of the forces exerted
on both sides of the hydraulic cylinder piston must be evaluated.

Figure 4

When making calculations for retracting the cylinder we will use the total available area on the rod side
annulus area including the spear area. The force created by pressure on this rod side must be counteracted
by the blind side piston area minus the spear area. From Figure 5 below we can see the rod side area of
58 square inches is working against an area of 89 square inches. This 89 sq in area must develop enough
back pressure to raise pressure on the rod side high enough to destroke the pressure compensated pump or

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 Hydraulic System for Spillway Gate Hoist Rehabilitation

the pump will continue to put out full flow. When system pressure gets high enough, the pump will start
to cut back output flow thus causing the cylinder velocity to slow down.

Figure 5

Some systems have high and low pressure pumps. When the first pump setting is reached cylinder
velocity will slow to the volume of the high pressure pump until that setting is reached. Figure 6 below
shows a chart recording of a typical two pressure system using the previous area examples. You can see
the velocity change in two steps and the resultant increase in ramp time to decelerate the cylinder rod. The
velocity changed from 1.5 in/sec to .25 in/sec in 9 seconds over just 3 inches of cylinder travel.

Figure 6

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This intensification of pressure created by forcing the fluid through progressively smaller holes gradually
compensates the pumps to reduce flow to the cylinders. The ratio of piston areas for retract stroke
direction is such that the greater area on the blind side is less than the rod side. However, when traveling
the opposite direction to extending the cylinder, it is extremely important to calculate pressure
intensification for the rod side of the cylinder. The area of the blind (piston) side working on the reduced
rod side area can produce extremely high pressures. These pressures can easily exceed 5000psi and
should be taken into consideration when calculating the cylinder end cap bolt holding capabilities. Figure
7 shows how quickly the pressures can intensify due to the large rod and spear diameters.

Figure 7

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Sizing Needle Valves

Most standard cylinder cushion needle valves are a “one size fits all” solution and are not suited for the
type of cushioning required for most civil engineering applications. They are generally sized for
maximum flows and have coarse thread adjustments that give little adjustability for low flow situations.
When using multiple needle valves they can be very small diameter orifices that will allow greater
adjustability at low flows. Most heavy civil engineering moving structures require a creep speed of
approximately 10% of the maximum travel speed. This varies of course for different applications but in
general, you want to decelerate from 100% speed to 10% speed in anywhere from 3-10 seconds. Once
creep speed has been achieved, it’s a matter of preference how long to creep to a stop.

Once you have established what pressures you will encounter the adjustable needle valves can be properly
sized to provide the necessary change in cylinder rod velocity. A standard fluid power formula is used for
calculation of flow through a sharp edge orifice (Area (sq. in.) = Q (gpm) ÷ (24.12 x √back pressure)).
This formula is also used for calculating the pressure drop across the nose of the cushion spear as it first
enters the cushion. Before needle valve orifice diameter can be determined you must first calculate the
stage 1 pressure drop created by the initial contact of the cushion spear. This stage 1 reaction is when the
high flow exiting the cylinder is very quickly restricted to the small orifices defined by the needle valves.
The cushion spear is machined with a small taper over the first ½” – ¾” of cushion spear (see Figure 8).
This taper provides the first stage of necessary backpressure to start de-stroking pump output.

Figure 8

In order to calculate the pressure drop through the spear taper you can take a snapshot of the available
flow area every 1/10” in the taper region. By adding these area snapshot pressure drops together you get
the pressure drop created during the stage 1 initial rise in pressure that occurs during the first second of
deceleration. Figure 9 shows a model of how this transition from full flow to restricted flow works. Once
the main exit path for the oil has been closed off by the cushion spear, all oil must now flow through the
needle valves. Pump output flow now starts to decrease causing the resultant flow through the needle
valves to be closer to the 10% target flow required.

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Figure 9

To size the needle valves take the intended creep speed flow and divide by the number of needle valves
used then apply the maximum pressure drop required to keep the pumps compensated. Remember that the
cushion spear has already increased the pumps to the threshold of the compensator setting. Reducing the
flow further as the spear progresses through the spear cavity, very little flow is being forced through the
final needle valve. Size the valves for their mid range flow capability so you will have the ability to adjust
final speed up or down. Typical needle valve sizing for most civil engineering applications is
approximately .16” diameter orifice sized needle valves.

Conclusion
Hydraulic cylinder cushions are a cost effective method for providing failsafe collision control of heavy
civil engineering moving structures. Progressive cushioning using multiple needle valves in a series
cavity arrangement can make the deceleration velocity curve infinitely adjustable to meet the needs of the
application.

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14 Biennial Movable Bridge Symposium
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Example with detailed calculations

The following example was taken from calculations and resultant chart recordings of the hydraulic system
used at the Matlacha Bridge in Matlacha Florida. It’s a single leaf bascule bridge driven by two hydraulic
cylinders 12.2”bore x 8.66” rod x 103.25” stroke. The leaf was moderately tip heavy by design and
required two 60 HP hydraulic pumps which each drove a double hydraulic pump. With a total of four
hydraulic pumps, two were set to compensate at 1850psi and two at 2650psi. You can see from chart
recording results the shop simulation testing was very similar to the actual final installed load testing.

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 Hydraulic Cylinder Cushion Analysis 

Steps  Page 

Step 1: System Data Collection ........................................................................ 2 

Step 2: Graph‐Target Flow and Compensator Pressure ................................... 3 ‐ 4 

Step 3: Pressure Drop Analysis......................................................................... 5 ‐ 6 

Step 4: Stage 3 Valve Selection ........................................................................ 7 ‐ 8 

Step 5: Stage 2 Valve Selection ........................................................................ 9 ‐ 10 

Step 6: Stage 1 Cushion Spear Dimension Verification .................................... 11‐ 12  

Step 7: Maximum Cushion Chamber Pressure Calculations for Stage 2 .......... 13 ‐16 

Step 8: Maximum Cushion Chamber Pressure Calculations for Stage 3 .......... 17 ‐20 

Prepared by: Steve Hanley @ EHM

Reviewed by: Mike Hanley @ EHM CFP #: 1145-R4

Signature: _______________________
 STEP 1: SYSTEM'S DATA COLLECTION
System Parameters  (Pump Selection/Cylinder Selection) Extend
Cylinder bore in inches 12.20
Cylinder stroke in inches (actual used stroke) 103.25
Rod diameter in inches 8.66
Cylinders per leaf 2.00
Pumps per leaf 4.00
Electric motor RPM 1800
Volumetric efficiency of pump  0.900
Horsepower of each dual pump 60.00
Mechanical efficiency of pump  0.80
Bore area in square inches 116.8
Annulus area in square inches 58.0
displacement rating required of each pump(cu in per rev) 4.62
Flow of each dual pump in gpm 32.40
Total actual pump flow available in gpm ( two dual pump sets) 129.60
Cylinders Extend Function Calculations
Time to accelerate extension in seconds 7.00
Time to deccelerate extension to creep speed in seconds 8.00
Time in extension creep speed in seconds 4.00
Total time to extend cylinders 63.00
Pressure drop to extend 567
Load pressure required to extend (Assume 700 PSI) 700
Total pressure to extend 1267
Total fluid in gallons to extend both cylinders 104.45
Maximum pump flow required in gallons per minute to extend both cylinders 112.92
Flow of each dual pump in gpm 56.46
motor horsepower required for normal operations  57.96
Motor horsepower selected for this project 60.00
If required HorsePower(HP) is greater than selected HP then HP limiting will be needed
Bridge leaf maximum velocity(feet/sec) 0.16

Cylinders Retract Function Calculations
Time to accelerate retraction in seconds 7.00
Time to deccelerate retraction to creep speed in seconds 8.00
Time in retraction creep speed in seconds 4.00
Total time to retract cylinders 63.00
Pressure drop to extend  939
Load pressure required to retract (Assume 200 PSI) 450
Total pressure to retract 1389
Maximum pump flow required in gallons per minute to retract both cylinders 56.02
Total fluid in gallons to retract both cylinders 51.82
Flow of each dual pump in gpm 28.01
motor horsepower required for normal operations 28.37
Motor horsepower selected for this project 60.00
Bridge leaf maximum velocity(feet/sec) 0.16

Pumps Compensator Settings
Pump 1 Compensator Setting (psi) 1500.00
Pump 2 Compensator Setting (psi) 2650.00

P. 2
 Step 2: Graph-Target Flows and Compensator Pressure

 This analysis is based on a worst case scenario where the limit switch has a failure
not reducing the speed, in which case the cushion will build pressure and pump
compensators will reduce flow to 25% of maximum seen in the charts below.

In the case of raising the bridge there are two active motors with four active pumps, two
pumps having compensators set at 1500 psi and two with compensators set at 2650 psi.
This demonstrates the change in flow as the pump reach set compensating value.

Page 3
 Step 2: Graph-Target Flows and Compensator Pressure

In the case of lowering the bridge there is one active motor and two active pumps, one
compensator set a 1500 psi and the other set at 2650 psi. Again showing the change in
flow characteristics as the pumps reach there compensating pressures.

Page 4
 Step 3: Pressure Drop Analysis

P1 R1 P1 R1
CYL PIPING CYL PIPING
P2 P2
CYL MFLD R2 CYL MFLD R2

P3 P3
P.O CHECK R3 P.O CHECK R3

P4 R4 P4 R4
FIELD PIPING FIELD PIPING

P5 R5 P5 R5
BALL VALVE BALL VALVE

P6 MANIFOLD R6
P6 MANIFOLD R6

P7 COUNTER BALANCE  R7 P7 COUNTER BALANCE  R7
VALVE VALVE

P8 R8 P8 R8
FIELD PIPING FIELD PIPING

P9 R9 P9 R9
BALL VALVE BALL VALVE

P10 R10 P10 R10

HPU MFLD HPU MFLD

P11 P11
R11 R11
DIRECTIONAL VALVE DIRECTIONAL VALVE

P12 P12
CHECK VALVE CHECK VALVE

FLOW METER FLOW METER R12

P13 PRESSURE FILTER P13 PRESSURE FILTER

RETURN FILTER R13 RETURN FILTER R13

P14 HPU PIPING R14 P14 HPU PIPING R14

P15
P15

Raising Lowering

Page 5
 Step 3: Pressure Drop Analysis

Pressure Drop for Extension Pressure Drop For Retraction

@ FLOW GPM PRESSURE DROP @ FLOW GPM PRESSURE DROP
P1 54.02 4 P1 27.01 2
P2 54.02 5 P2 27.01 5
P3 54.02 7 P3 27.01 4
P4 54.02 10 P4 27.01 3
P5 54.02 10 P5 27.01 5
P6 108.00 30 P6 54.02 30
P7 54.02 150 P7 54.02 150
P8 108.00 35 P8 54.02 31
P9 108.00 17 P9 54.02 8
P10 108.00 50 P10 54.02 50
P11 108.00 20 P11 54.02 10
P12 54.02 5 P12 54.02 5
P13 54.02 8 P13 54.02 8
P14 27.00 5 P14 27.00 3
P15 54.02 0 P15 54.02 0

Pressure Lost 356 Pressure Lost 314

Differential Area 189 Differential Area 626

@ FLOW GPM PRESSURE DROP @ FLOW GPM PRESSURE DROP

R1 27.01 7 R1 54.02 7
R2 27.01 5 R2 54.02 5
R3 27.01 5 R3 54.02 5
R4 27.01 7 R4 54.02 7
R5 27.01 10 R5 54.02 10
R6 27.01 30 R6 54.02 30
R7 54.02 200 R7 54.02 100
R8 54.02 31 R8 54.02 31
R9 54.02 10 R9 54.02 8
R10 54.02 50 R10 108 55
R11 54.02 5 R11 108 20
R12 54.02 15 R12 108 25
R13 54.02 3 R13 108 10
R14 54.02 0 R14 108 0

Pressure Lost 378 Pressure Lost 313

Pressure Require to Move Fluid 567 Pressure Require to Move Fluid 939
HP Require to Move Fluid 17.88052539 HP Require to Move Fluid 29.61166375

Page 6
 Step 4: Stage 3 Valve Selection

Stage 3 Parameters
@ FLOW GPM PRESSURE
P1 13.51 2614.40
Stage 3 Free Body Diagram Extension
P15 ****** 2650.00
Compensator setting 2650.00
Pressure Lost 35.6

R14 R1
R1 6.75 37.8
R14 ******** 0
Pressure Lost 37.8
Valve 4

Valve 3

Cushion Spears

P15 P1

Valve 1

Valve 2

Cushion Cavity

Stage 3:
Stage 3 is one needle valve only and begins after the cushion spear is approximately 1/2 inch past Valve 1.
It is important that Valve 2 never gets covered up by the cushion spear else all flow would stop.
This cylinder will be installed such that the last 0.5 inch of stroke is not used,
so Valve 2 can be placed there and not get covered by the cushion.
Table 3:Cushion Data during extension@stage 3
Extension Flow thru valve 4 @ stage 3
Rod end Flow thru Valve 4 @ stage 3 6.75 GPM
Total rod end flow @ stage 3 6.75 GPM
Cushion pressure Raising (PRC-PR)=DP 5731 PSI
Valve 4 Diameter Raising 0.069 in
2
Valve 4 Area Raising 0.0037 in

P. 7
 Step 4: Stage 3 Valve Selection

Stage 3 Free Body Diagram Retraction

P15 P1

Valve 3

Valve 4

R14 R1
Cushion Spears

Valve 1

Valve 2

Cushion Cavity

Stage 3 Parameters
@ FLOW GPM PRESSURE

P1 6.75 2618.60
P15 ******* 2650.00
Compensator setting 2650.00
Pressure Lost 31.40

R1 13.505 31.30
R14 ******** 0
Pressure Lost 31.30

Stage 3:

Stage 3 is one needle valve only and begins after the cushion spear is approximately 1/2 inch past Valve 1.
It is important that Valve 2 never gets covered up by the cushion spear else all flow would stop
stop.
This cylinder will be installed such that the last 0.5 inch of stroke is not used,
so Valve 2 can be placed there and not get covered by the cushion.
Table 3:Cushion Data during retract@stage 3
Retracting Flow thru valve 2 @ stage 3
Blind end Flow thru Valve 2 @ stage 3 13.51 GPM
Total blind end flow @ stage 3 13.51 GPM Step 2

Cushion pressure lowering (PBC-PB)=DP 1642 PSI Step 3

Valve 2 Diameter lowering 0.133 in Step 4

2
Valve 2 Area lowering 0.0138 in

P. 8
 Step 5: Stage 2 Valve Selection

Stage 2 Free Body Diagram Extension

R14 R1

Valve 4

Valve 3
Cushion Spears

P15 P1

Valve 1

Valve 2

Cushion Cavity

Stage 2 Parameters
@ FLOW GPM PRESSURE
P1 27.01 1322.00
P15 ******** 1500.00
Table 2 Pertinent Compensator setting 1500.00
Equations Pressure Lost 178

Effective Orifice Area/ R1 13.505 189

Valve Diameter: R14 ******** 0
Pressure Lost 189
A( sq .in )  Q (GPM )
24 .12  Back pressure 
Diameter of Individual
Valve:
 4   A ( sq .in )  
D (in )   
  
Table 2: Cushion Data during extension@ stage -2 at 1500 PSI
Rod end Flow thru Valve 3 @ stage 2 8.59 GPM
Rod end Flow thru Valve 4 @ stage 2 4.91 GPM
Total Rod end flow @ stage 2 13.51 GPM
Cushion pressure Raising (PRC-PR)=P 3036 PSI
Valve 3 Diameter Raising 0.091 in
2
Valve 3 Area Raising 0.0065 in

P. 9
 Step 5: Stage 2 Valve Selection

Stage 2 Free Body Diagram Retraction

P15 P1

Valve 3

Valve 4

R14 R1 Cushion Spears

Valve 1

Valve 2

Cushion Cavity

Stage 2 Parameters
@ FLOW GPM PRESSURE
P1 13.51 1343.00
P15 ********* 1500.00
Table 2 Pertinent
Compensator setting 1500 00
1500.00
Equations
Pressure Lost 157
Effective Orifice Area/
Valve Diameter: R1 27.01 156.5
R14 ********* 0
A( sq .in )  Q (GPM )
24 .12  Back pressure  Pressure Lost 156.5

Diameter of Individual
Valve:
 4   A ( sq .in )  
D (in )   
  

Table 2: Cushion Data during retract@ stage -2 at 1500 PSI

Blind end Flow thru Valve 1 @ stage 2 17.27 GPM
Blind end Flow thru Valve 2 @ stage 2 9.74 GPM
Total blind end flow @ stage 2 27.01 GPM
Cushion pressure lowering (PBC-PB)=P 855 PSI
Valve 1 Diameter lowering 0.177 in
2
Valve 1 Area Lowering 0.0245 in

P. 10
 Step 6: Stage 1 Cushion Spear Dimension Verification

Stage 1 Free Body Diagram Extension

Stage 1 is just before the pump

R14 R1
begins to compensate.
We need to know where is
the cushion spear, at the moment
that the pump begins to compensate
Valve 4
This point is 100PSI before
Valve 3
Cushion Spears
compensator setting

Stage 1 Parameters
@ FLOW GPM PRESSURE
P15 P1 P1 54.02 1044.00
P15 ******* 1400.00
Compensator setting 1500.00
Valve 1
Pressure Lost 356
Valve 2

Cushion Cavity
R1 27.01 378
R14 ******* 0
Pressure Lost 378

When compensation begins, cushion Chamber press will be @ 2104 PSI

Flow thru Valve # 4 will be 3.7 GPM
Flow thru valve # 3 will be 6.5 GPM
Flow thru the cushion spear clearance hole will be. 16.8 GPM

Cushion dimensional information

Cavity spear spear taper 3 degree over 0.625 inch
9.2507 9.2489

Find the distance into the cavity when the pressure drop equals the cushion chamber pressure above
Distance spear dia area diff press drop
0.1 9.1239 1.8301 0.1 The pressure drop was calculated using the formula for a sharp edge
orifice. The formula has limits on the travel distance. Different points were
0.2 9.1489 1.4713 0.2
calculated to total the sum for .6" distance of travel. The table on the left
0.3 9.1739 1.1115 0.5 represents the individual pressure drops at each distance point. The table
0.4 9.1989 0.7507 2.5 below is the total pressure drop by adding up all the individual points.
0.5 9.2239 0.3889 34.6
0.55 9.2329 0.2584 177.6
0.575 9.2379 0.1859 663 At a distance of 0.6 inch of travel
0.6 9.2399 0.1569 1309 the pressure drop is 2187.5 PSI
so it is at this point that the slowdown will begin

Using the the free body diagram we were able to determine the flows and back pressure at each stage
of cushing. This allowed us to determine the proper valve sizing for the second and thrid stage. Using
the pressure difference in stage one of 378 pounds per square inch it was determine that we will have
late cushioning after the critical point (.9 inch of travel) or one tenth after entering the cavity .

P.11
 Step 6: Stage 1 Cushion Spear Dimension Verification

Stage 1 Free Body Diagram Retraction Stage 1 is just before the pump
begins to compensate.
We need to know where is
the cushion spear, at the moment
that the pump begins to compensate
P15 P1 This point is 100PSI before
compensator setting

Valve 3

Valve 4

Cushion Spears Stage 1 Parameters

R14 R1
@ FLOW GPM PRESSURE
P1 27.01 1086
Valve 1 P15 ******* 1400
Compensator setting 1500.00
Valve 2
Pressure Lost 314
Cushion Cavity
R1 54.02 313
R14 ******* 0
Pressure Lost 313

When compensation begins Pressure in cushion Chamber will be @ 538.8 PSI

Table 1: Cushion Data during retract @ Stage 1

When compensation begins, cushion Chamber press will be @ 539 PSI
Flow thru Valve # 4 will be 5.0 GPM
Flow thru valve # 3 will be 8.9 GPM
Flow thru the cushion spear clearance hole will be. 40.1 GPM

Cushion dimentional information

Cavity spear spear taper 3 degree over 0.625 inch
6 5.998

Find the distance into the cavity when the pressure drop equals the cushion chamber pressure above
Distance spear dia area diff press drop
0.1 5.8730 1.1844 2.3 The pressure drop was calculated using the formula for a sharp edge orifice.
The formula has limits on the travel distance. Different points were
0.2 5.8980 0.9533 5.5 calculated to total the sum for .475" distance of travel. The table on the left
0.3 5.9230 0.7211 16.7 represents the individual pressure drops at each distance point. The table
0.4 5.9480 0.4880 79.5 below is the total pressure drop by adding up all the individual points.
0.45 5.9530 0.4413 118.9
0.475 5.9630 0.3477 308.5
At a distance of 0.475 inch of travel
the pressure drop is 531.2 PSI
so it is at this point that the slowdown will begin

P.12
 Step 7: Maximum Cushion Chamber Pressure Calculations for Stage 2

Calculation of Cushioning
Subject Matter: Raising of Bridge Leaf (extending cylinder)
The calculations below represent a compensator setting of 1500 psi. This occurs during stage 2 of
cushioning.-The goal is to determine PC which is shown at the end of the next page.
Load

Travel
Return Flow
ARa
Tank Valve & line drop

RCSa
Outlet
Flow
RSPa

PTa Inlet flow

Pc Valve & line drop
BSPa
Pump
ACSa
Inlet
Flow

Fig. 2 Cylinder Raising

Note:
The back-pressure can be adjusted by opening or closing the needle valves
thereby controlling the cushioning. This cushion device would only be
used in a worst case scenario where electronic controls (limit switches)
fail. First, the required back pressure to decelerate the mass of the bridge is
calculated. Typically the mass energy is only about 10% to 20% of the
total energy that needs to be converted to heat by the cushion.
Second the required back pressure to cause the pressure compensator
control on the pump to de-stroke and therefore slow the bridge movement.
Third, the required orifice area that produces the required back pressure is
calculated and appropriate valves are selected (refer to table 2 and BOM).

Page 13
 Step 7: Maximum Cushion Chamber Pressure Calculations for Stage 2
Cushion Data:

Cushion spear diameter Hollow around the piston rod Ds = 9.25 in

Surface area of rod end cushion spear RCS = 8.30 in2
2
Rod side piston area after cushion spear enters cavity BSPa = 49.67 in

Calculations:

Initial Velocity vo = 0.155 ft/secs

Final Velocity which is 50% of initial velocity vi = 0.074 ft/secs
2
Average Cushion deceleration ac = 0.041 ft/secs
Cushion stopping time tc = 2.00 secs
Estimated mass of bridge Mb = 1463500 slugs
Total number of cylinders holding up the bridge NC = 2
Force of deceleration of leaf moving mass on one cylinder Fb = 29.65 kips

Pressure @ pump outlet PP = 1500 psi

Pressure drop across inlet flow piping and valves PDIF = 356 psi
Pressure @ cylinder blind side Pr = 1144 psi
Determinative pushing force Cylinder blind side: Frs = 133.66 kips

Pressure drop across outlet flow piping and valves PDOF = 378
Pressure @ cylinder rod side port port connection PBP = 378
Determinative pushing force Cylinder Rod side cushion spear: Fcs = 3.14 kips

Force seen by Cylinder Rod side Fbs = 160.18 kips

F F F F
bs rs b cs
Back-pressure at Gauge Pc rod side Pc = 3225 psi
Fbs
Pc 
B SPa

Page 14
 Step 7: Maximum Cushion Chamber Pressure Calculations for Stage 2

Calculation of Cushioning
Subject Matter: Lowering of Bridge Leaf(retracting cylinder )
The calculations below represent a compensator setting of 1500 psi. This occurs during stage 2
of cushioning.-The goal is to determine PC which is shown at the end of the next page.
Load

Travel
Inlet flow
Valve & line drop
Pump
ARa
Inlet
Flow

RSPa
Return Flow
Valve & line drop
Pc
PTa
Tank
BSPa Outlet
Flow

ACS a

Fig. 2 Cylinder A in Retraction

Note:
The back-pressure can be adjusted by opening or closing the needle valves
thereby controlling the cushioning. This cushion device would only be used
in a worst case scenario where electronic controls (limit switches) fail. First,
the required back pressure to decelerate the mass of the bridge is calculated.
Typically the mass energy is only about 10% to 20% of the total energy that
needs to be converted to heat by the cushion.
Second the required back pressure to cause the pressure compensator
control on the pump to de-stroke and therefore slow the bridge movement.
Third, the required orifice area that produces the required back pressure is
calculated and appropriate valves are selected (refer to table 2 and BOM).

Page 15
 Step 7: Maximum Cushion Chamber Pressure Calculations for Stage 2
Cushion Data:
Cushion spear diameter Ds = 6 in
2
Surface area of cushion spear shaft ACSa = 28.27 in
2
Blind side piston area after cushion spear enters cavity BSPa = 88.57 in

Calculations:

Initial Velocity vo = 0.155 ft/secs

Final Velocity which is 50% of initial velocity vi = 0.074 ft/secs
2
Average Cushion deceleration ac = 0.041 ft/secs
Cushion stopping time tc = 2.00 secs
Estimated mass of bridge Mb = 1463500 slugs
Total number of cylinders holding up the bridge NC = 2
Force of deceleration of leaf moving mass on one cylinder Fb = 29.65 kips

Pressure @ pump outlet PP = 1500 psi

Pressure drop across inlet flow piping and valves PDIF = 314 psi
Pressure @ cylinder rod side Pr = 1186 psi
pushing force Cylinder (rod side): Frs = 68.75 kips

Pressure drop across outlet flow piping and valves PDOF = 313
Pressure @ cylinder blind side port port connection PBP = 313
pushing force Cylinder blind side cushion spear: Fcs = 8.85 kips

Force seen by Cylinder B (blind side) Fbs = 89.55 kips

F F F F
bs rs b cs
Back-pressure at Gauge Pc (blind side) Pc = 1011 psi
Fb s
Pc 
BSPa

Page 16
 Step 8: Maximum Cushion Chamber Pressure Calculations for Stage 3

Calculation of Cushioning
Subject Matter: Raising of Bridge Leaf (extending cylinder)
The calculations below represent a compensator setting of 2650 psi. This occurs during stage 3 of
cushioning.-The goal is to determine PC which is shown at the end of the next page.
Load

Travel
Return Flow
ARa
Tank Valve & line drop

RCSa
Outlet
Flow
RSPa

PTa Inlet flow

Pc Valve & line drop
BSPa
Pump
ACSa
Inlet
Flow

Fig. 2 Cylinder Raising

Note:
The back-pressure can be adjusted by opening or closing the needle valves
thereby controlling the cushioning. This cushion device would only be
used in a worst case scenario where electronic controls (limit switches)
fail. First, the required back pressure to decelerate the mass of the bridge is
calculated. Typically the mass energy is only about 10% to 20% of the
total energy that needs to be converted to heat by the cushion.
Second the required back pressure to cause the pressure compensator
control on the pump to de-stroke and therefore slow the bridge movement.
Third, the required orifice area that produces the required back pressure is
calculated and appropriate valves are selected (refer to table 2 and BOM).

Page 17
 Step 8: Maximum Cushion Chamber Pressure Calculations for Stage 3
Cushion Data:

Cushion spear diameter Hollow around the piston rod Ds = 9.25 in

Surface area of rod end cushion spear RCS = 8.30 in2
2
Rod side piston area after cushion spear enters cavity BSPa = 49.67 in

Calculations:

Initial Velocity vo = 0.074 ft/secs

Final Velocity which is 20% of initial velocity vi = 0.015 ft/secs
2
Average Cushion deceleration ac = 0.030 ft/secs
Cushion stopping time tc = 2.00 secs
Estimated mass of bridge Mb = 1463500 slugs
Total number of cylinders holding up the bridge NC = 2
Force of deceleration of leaf moving mass on one cylinder Fb = 21.66 kips

Pressure @ pump outlet PP = 2650 psi

Pressure drop across inlet flow piping and valves PDIF = 356 psi
Pressure @ cylinder blind side Pr = 2294 psi
Determinative pushing force Cylinder blind side: Frs = 268.03 kips

Pressure drop across outlet flow piping and valves PDOF = 378
Pressure @ cylinder rod side port port connection PBP = 378
Determinative pushing force Cylinder Rod side cushion spear: Fcs = 3.14 kips

Force seen by Cylinder Rod side Fbs = 286.55 kips

F F F F
bs rs b cs
Back-pressure at Gauge Pc rod side Pc = 5769 psi
Fbs
Pc 
B SPa

Page 18
 Step 8: Maximum Cushion Chamber Pressure Calculations for Stage 3

Calculation of Cushioning
Subject Matter: Lowering of Bridge Leaf(retracting cylinder )
The calculations below represent a compensator setting of 2650 psi. This occurs during stage 3
of cushioning.-The goal is to determine PC which is shown at the end of the next page.
Load

Travel
Inlet flow
Valve & line drop
Pump
ARa
Inlet
Flow

RSPa
Return Flow
Valve & line drop
Pc
PTa
Tank
BSPa Outlet
Flow

ACS a

Fig. 2 Cylinder A in Retraction

Note:
The back-pressure can be adjusted by opening or closing the needle valves
thereby controlling the cushioning. This cushion device would only be used
in a worst case scenario where electronic controls (limit switches) fail. First,
the required back pressure to decelerate the mass of the bridge is calculated.
Typically the mass energy is only about 10% to 20% of the total energy that
needs to be converted to heat by the cushion.
Second the required back pressure to cause the pressure compensator
control on the pump to de-stroke and therefore slow the bridge movement.
Third, the required orifice area that produces the required back pressure is
calculated and appropriate valves are selected (refer to table 2 and BOM).

Page 19
 Step 8: Maximum Cushion Chamber Pressure Calculations for Stage 3
Cushion Data:
Cushion spear diameter Ds = 6 in
2
Surface area of cushion spear shaft ACSa = 28.27 in
2
Blind side piston area after cushion spear enters cavity BSPa = 88.57 in

Calculations:

Initial Velocity vo = 0.074 ft/secs

Final Velocity which is 20% of initial velocity vi = 0.015 ft/secs
2
Average Cushion deceleration ac = 0.030 ft/secs
Cushion stopping time tc = 2.00 secs
Estimated mass of bridge Mb = 1463500 slugs
Total number of cylinders holding up the bridge NC = 2
Force of deceleration of leaf moving mass on one cylinder Fb = 21.66 kips

Pressure @ pump outlet PP = 2650 psi

Pressure drop across inlet flow piping and valves PDIF = 314 psi
Pressure @ cylinder rod side Pr = 2336 psi
pushing force Cylinder (rod side): Frs = 135.41 kips

Pressure drop across outlet flow piping and valves PDOF = 313
Pressure @ cylinder blind side port port connection PBP = 313
pushing force Cylinder blind side cushion spear: Fcs = 8.85 kips

Force seen by Cylinder B (blind side) Fbs = 148.22 kips

F F F F
bs rs b cs
Back-pressure at Gauge Pc (blind side) Pc = 1674 psi
Fb s
Pc 
BSPa

Page 20