Module-III
ME-503 (Hydraulics & Pneumatic Controls)
Hydraulic circuit design and analysis
Hydraulic circuits
Control of a double acting hydraulic cylinder circuit
Regenerative circuit
• Regenerative circuit used to accelerate the extending speed of the double
acting hydraulic cylinder.
• In this system, both ends of the hydraulic cylinder are connected in parallel and one of
the ports of the four-way valve is blocked. The operation of the cylinder during the
retraction stroke is the same as that of a regular double acting cylinder.
• Fluid flows through the DCV (direction control valve) via the right envelope during the
retraction stroke. In this mode the fluid from the pump bypasses the DCV and enters the
rod end of the cylinder. Fluid in the blank end drains back to the tank through the DCV
as the cylinder retracts.
• When the DCV is shifted to the left envelope configuration, the cylinder extends. The
speed of extension is greater than that for a regular double acting cylinder. This is
because the flow from the rod end (QR) regenerates with the pump flow (QP) to provide
a total flow rate (QT), which is greater than the pump flow rate to the blank end of the
cylinder.
• The total flow rate entering the blank end of the cylinder equals the pump flow rate plus
the regenerative flow rate coming from the rod end of the cylinder.
So, extending speed of the piston
or,
and retracting speed of the piston
𝑉𝑃𝑒𝑥𝑡 𝐴𝑃 − 𝐴𝑅 𝐴𝑃
Ratio = = −1
𝑉𝑃𝑟𝑒𝑡 𝐴𝑅 𝐴𝑅
• The load-carrying capacity of a regenerative cylinder during extension is less
than that obtained from a regular double-acting cylinder.
• The load-carrying capacity for a regenerative cylinder during extension equals
the pressure times the piston rod area rather than the pressure times piston
area. This is because system pressure acts on both sides of the piston during
the extending stroke of the regenerative cylinder.
Flext = pAR
• Thus, we are not obtaining more power from the regenerative cylinder
during extension because the extending speed is increased at the expense of
reduced load carrying capacity.
Drilling Machine Application
Example of regenerative circuit
A double-acting cylinder is hooked up in the regenerative circuit of Figure. The
cracking pressure for the relief valve is 1000 Pa. The piston area is 25 m2 and the
rod area is 7 m2. The pump flow is 77 m3/s. Find the cylinder speed, load-carrying
capacity, and power delivered to the load (assuming the load equals the cylinder
load-carrying capacity) during the
a. Extending stroke
b. Retracting stroke
Pump unloading circuit
In this circuit using an unloading valve to
unload a pump. The unloading valve
opens when the cylinder reaches the end
of its extension stroke because the check
valve keeps high-pressure oil in the pilot
line of the unloading valve. When the DCV
is shifted to retract the cylinder, the
motion of the piston reduces the pressure
in the pilot line of the unloading valve.
This resets the unloading valve until the
cylinder is fully retracted, at which point
the unloading valve unloads the pump.
Thus, the unloading valve unloads the
pump at the ends of the extending and
retraction strokes as well as in the spring-
centered position of the DCV.
DOUBLE-PUMP HYDRAULIC SYSTEM
• This circuit uses a high-pressure, low-
flow pump in conjunction with a low-
pressure, high-flow pump.
• A typical application is a sheet metal
punch press in which the hydraulic ram
(cylinder) must extend rapidly over a
great distance with very low pressure
but high flow-rate requirements.
• This rapid extension of the cylinder
occurs under no external load as the
punching tool (connected to the end of
the cylinder piston rod) approaches the
sheet metal strip to be punched.
• However, during the short motion portion when the punching operation occurs,
the pressure requirements are high due to the punching load. During the punching
operation, the cylinder travel is small and thus the flow-rate requirements are low.
• It eliminates the necessity of having a very expensive high pressure, high-flow
pump.
• When the punching operation begins, the
increased pressure opens the unloading
valve to unload the low-pressure pump.
The purpose of the relief valve is to
protect the high-pressure pump from
overpressure at the end of the cylinder
stroke and when the DCV is in its spring-
centered mode. The check valve protects
the low-pressure pump from high
pressure, which occurs during the
punching operation, at the ends of the
cylinder stroke, and when the DCV is in its
spring-centered mode.
COUNTERBALANCE VALVE APPLICATION
The use of a counterbalance or back-
pressure valve to keep a vertically
mounted hydraulic cylinder in the
upward position while the pump is
idling. The counterbalance valve (CBV)
is set to open at somewhat above the
pressure required to prevent the
vertical cylinder from descending due
to the weight of its load. This permits
the cylinder to be forced downward
when pressure is applied on the top.
The open-center directional control
valve unloads the pump. The DCV is a
solenoid-actuated, spring-centered
valve with an open-center flow path
configuration.
HYDRAULIC CYLINDER SEQUENCING CIRCUITS
• Two sequence valves are used to control the sequence of operations of two double-acting
cylinders.
• When the DCV is shifted into its left envelope mode, the left cylinder extends completely,
and then the right cylinder extends.
• If the DCV is then shifted into its right envelope mode, the right cylinder retracts fully, and
then the left cylinder retracts.
• This sequence of cylinder operation is controlled by the sequence valves. The
spring-centered position of the DCV locks both cylinders in place.
• One application of this circuit is a production operation. For example, the left
cylinder could extend and clamp a workpiece via a power vise jaw. Then the right
cylinder extends to drive a spindle to drill a hole in the workpiece. The right
cylinder then retracts the drill spindle, and then the left cylinder retracts to
release the workpiece for removal.
• Obviously these machining operations must occur in the proper sequence as
established by the sequence valves in the circuit.
LOCKED CYLINDER USING PILOT CHECK VALVES
In many cylinder applications, it is
necessary to lock the cylinder so that its
piston cannot be moved due to an
external force acting on the piston rod.
One method for locking a cylinder in this
fashion is by using pilot check valves, as
shown in Figure. The cylinder can be
extended and retracted as normally done
by the action of the directional control
valve. If regular check valves were used,
the cylinder could not be extended or
retracted by the action of the DCV. An
external force, acting on the piston rod,
will not move the piston in either
direction because reverse flow through
either pilot check valve is not permitted
under these conditions.
CYLINDER SYNCHRONIZING CIRCUITS
Two identical cylinders can be synchronized by piping them in parallel. However,
even if the two cylinders are identical, it would be necessary for the loads on the
cylinders to be identical in order for them to extend in exact synchronization. If
the loads are not exactly identical (as is always the case), the cylinder with the
smaller load would extend first because it would move at a lower pressure level.
After this cylinder has fully completed its stroke, the system pressure will increase
to the higher level required to extend the cylinder with the greater load. It should
be pointed out that no two cylinders are really identical. For example, differences
in packing friction will vary from cylinder to cylinder. This alone would prevent
cylinder synchronization for the circuit.
Cylinders Connected in Series
The circuit shows that hooking two cylinders in series is a simple way to synchronize
the two cylinders. For example, during the extending stroke of the cylinders, fluid
from the pump is delivered to the blank end of cylinder 1 via the flow path shown in
the upper envelope of the DCV. As cylinder 1 extends, fluid from its rod end is
delivered to the blank end of cylinder 2. Note that both ends of cylinders and the
entire pipeline between the cylinders is filled with fluid. Fluid returns to the oil tank
from the rod end of cylinder 2, as it extends, via the DCV. For the two cylinders to be
synchronized, the piston area of cylinder 2 must equal the difference between the
areas of the piston and rod for cylinder 1. This can be shown by applying the
continuity equation which states that the rate at which fluid leaves the rod end of
cylinder 1 must equal the rate at which fluid enters cylinder 2. Thus, we have for a
hydraulic fluid
It should be noted that the pump must be capable of delivering a pressure equal to that
required for the piston of cylinder 1 by itself to overcome the loads acting on both
extending cylinders.
The pressures are equal at the blank end of cylinder 2 and at the rod end of cylinder 1 per
Pascal’s law
SPEED CONTROL OF A HYDRAULIC CYLINDER
Operation
A circuit where speed control of a hydraulic cylinder is accomplished during the
extension stroke using a flow control valve. The operation is as follows:
• When the directional control valve is actuated, oil flows through the flow control valve to
extend the cylinder. The extending speed of the cylinder depends on the setting (percent
of full opening position) of the flow control valve (FCV).
• When the directional control valve is de-actuated into its spring-offset mode, the
cylinder retracts as oil flows from the cylinder to the oil tank through the check valve as
well as the flow control valve.
Analysis of Extending Speed Control
• During the extension stroke, if the flow control valve is fully open, all the flow from the
pump goes to the cylinder to produce maximum cylinder speed.
• As the flow control valve is partially closed its pressure drop increases. This causes an
increase in pressure p1. Continued closing of the flow control valve ultimately results in
pressure p1 reaching and exceeding the cracking pressure of the pressure relief valve
(PRV). The result is a slower cylinder speed since part of the pump flow goes back to the
oil tank through the PRV.
• For the desired cylinder speed, pressure p1 approximately equals the PRV setting, and the
amount of pump flow that is not desired by the cylinder flows through the PRV.
• An analysis to determine the extending speed is given as follows:
The flow rate to the cylinder equals pump flow rate minus the flow rate through the
PRV.
The flow rate through the flow control valve (FCV)
Pressure p2 can be obtained
and
Meter-In Systems
• A meter-in flow control system, in which the flow control valve is placed in the
line leading to the inlet port of the cylinder. Hence a meter-in flow control
system controls the oil flow rate into the cylinder.
• Meter-in systems are used primarily when the external load opposes the
direction of motion of the hydraulic cylinder.
• If the flow control valve were not to be located, the extension and retraction of
the actuator which in this case is a cylinder, would have proceeded at an
unrestricted rate.
• The presence of the flow control valve enables restriction in the fluid flow to
the cylinder and thereby slowing down its extension.
• In the event of the flow direction being reversed, the check valve ensures that
the return flow bypasses the flow control valve.
• For the same meter-in operation, shows shifting of the flow control to the other
line. This enables the actuator to extend at an unrestricted rate but conversely
the flow to the actuator during the retracting operation can be restricted so that
the operation takes place at a reduced rate.
• The meter-in operation is quite accurate with a
positive load. But with an Overrunning load over
which the actuator has no control, the cylinder
begins to cavitate.
Meter-Out System
• A meter-out flow control
system is one in which
the flow control valve is
placed in the outlet line
of the hydraulic cylinder.
A meter-out flow control
system controls the oil
flow rate out of the
cylinder.
• It is the opposite of a meter-in operation as this change in direction will cause the
fluid leaving the actuator to be metered. The advantage with the meter-out
operation is that unlike in the case of meter-in operation, the cylinder here is
prevented from overrunning and consequent cavitating.
SPEED CONTROL OF A HYDRAULIC MOTOR
Speed control of a hydraulic motor is accomplished using a pressure-compensated
flow control valve.
hydraulic motor braking system
When using a hydraulic motor in a fluid power system, consideration should be
given to the type of loading that the motor will experience. A hydraulic motor may
be driving a machine having a large inertia. This would create a flywheel effect on
the motor, and stopping the flow of fluid to the motor would cause it to act as a
pump. In a situation such as this, the circuit should be designed to provide fluid to
the motor while it is pumping to prevent it from pulling in air. In addition, provisions
should be made for the discharge fluid from the motor to be returned to the tank
either unrestricted or through a relief valve. This would stop the motor rapidly but
without damage to the system. Figure shows a hydraulic motor braking circuit that
possesses these desirable features for either direction of motor rotation.
HYDROSTATIC TRANSMISSION SYSTEM
Closed-Circuit Diagrams
MECHANICAL-HYDRAULIC SERVO SYSTEM
• An automotive power-steering
example of a mechanical-hydraulic
servo system (closed-loop system).
1.
2.
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