Introduction to

Hydraulic Circuits
Dr. Abdel-Halim Saber
Welcome to the Session on :

HYDRAULIC CIRCUITS

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1. Application of Hydraulics

• Mobile Hydraulics • Stationary Hydraulics

• Earth moving equipment • Hydropower waterways gates
• Folk Lift Truck, Car Jacks, etc • Hydropower Governor System, etc
 Introduction
 A hydraulic circuit is a group of components including one or more pump,
actuators, valves, piping, and ancillary equipment. It is used for power
transmission and control.

Hydraulic Valve Fxv

Hydraulic
Cylinder

VxI Txω
Electric Hydraulic
Motor Pump

PxQ Txω
Hydraulic
Motor
 HYDRAULIC CIRCUITS

MOTOR & PRESSURE

PUMP CONTROL
VALVES

HYDRAULIC FLOW
ACTUATORS CONTROL
POWER VALVES
UNIT

DIRECTION
ACCESSORIES CONTROL
VALVES

7
2. Parts of a Hydraulic System

Representation of a Hydraulic System

A Hydraulic system can be divided
into two sections:
(a)Signal control section, and
(b)Hydraulic power section

Diagrammatic representation of the structure of a hydraulic system

2. Parts of a Hydraulic System

Signal control section

The Signal section is divided into signal input (sensing) and signal processing (processing).

Signal input can be:

• Manual
• Mechanical
• Contactless
Signal can be
processed by:
• Operator
• Electricity
• Electronics
• Pneumatics
• Mechanics
• Hydraulics
 2. Parts of a Hydraulic System

The Hydraulic power section – has three sections: Power supply section - energy conversion :
• Power supply section electrical->mechanical->hydraulic:
• Power control section Power supply components are -
• Drive section • Electric motor/ or gas engine
• Coupling
• Pump
• Pressure indicator
• Protective Circuitry
Components used to condition the fluid are:
• Filter
• Cooler /or Heater
• Thermometer
• Pressure gauge
• Reservoir
• Filling level indicator
2. Parts of a Hydraulic System

Power control section

The fluid power is supplied to the drive section by
the power control section . Components
used are:
• Direction control valves
• Pressure valves
• Non-return valves
• Flow control valves
Drive section
This is the part that executes the various working
movements of a machine or equipment.
The drive components are:
• Cylinders
• Motors
 HYDRAULIC CIRCUITS

A GOOD HYDRAULIC SYSTEM REQUIREMENT -

SATISFY THE SPECIFICATIONS OF THE OPERATION WITH
SAFETY
PERFORM SMOOTH OPERATION
LOW ENERGY CONSUMPTION – LOW HEAT GENERATION
REDUCE INITIAL COST & RUNNING COST
MAKE MAINTENANCE EASY

HYDRAULIC CIRCUITS ARE GRAPHICAL DIAGRAMS

OF THE HYDRAULIC SYSTEMS.
IT ALSO INDICATES EACH OPERATION OF THE
COMPONENTS.
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 Hydraulic Circuits
 Single Acting Hydraulic Cylinder Control Circuit
 Double Acting Hydraulic Cylinder Control Circuit
 Regenerative Cylinder Circuit
 Pump Unloading Circuit
 Double Pump Circuit
 Counterbalance Valve Circuits
 Cylinder Sequencing Circuits
 Locked Cylinders using Pilot Check Valves
 Cylinder Synchronization Circuits
 Fail Safe Circuits
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
Single Acting Hydraulic Cylinder Control
Circuit
 Single Acting Hydraulic Cylinder Control
Circuit
Analysis Objectives

Given:
• Load carrying capacity
• Extension speed
• Retraction speed

What are the objective of design analysis?

 Single Acting Hydraulic Cylinder Control
Circuit
Analysis Objectives
 Pump
 Flow rate
 Pressure Head
 Type
 Pressure Relief Valve
 Cracking pressure
 Full Open pressure
 Size
 Spring
 Stiffness
 Initial Compression
 Single Acting Hydraulic Cylinder Control
Circuit
Design Optimization

What are the objective of

design optimization?
 Single Acting Cylinder Control Circuit
Design Optimization
 Improve efficiency (operating cost)
 Reduce size and weight
 Increase safety
 Reduce cost
 Simplify operation
 Improve functionality
 Allow to stop during stroke
 Allow servo control
 Increase retraction speed
 …..
 Extend working life
 Reduce noise
 Improve reliability
 Reduce pollution and environmental
effects
 …
Double Acting Cylinder Control Circuit

Extend Hold Retract

 Double Acting Cylinder Control Circuit

Hold Retract
Extend
 Automatic Cylinder Reciprocating System
 Two sequence valves sense a 0.00 Bar
0.00 Bar
stroke completion by
corresponding buildup of
pressure. Each check valve and
corresponding pilot line
prevents shifting of the
directional control valve until
the particular stroke of the
cylinder has been completed. 0.00 Bar

 The check valves are needed to

allow pilot oil to leave either
end of the DCV while pilot
pressure is applied to the
opposite end. This permits the
spool of the valve to move as
required.
Automatic cylinder Reciprocating System
 Flow and pressure analysis in the automatic
reciprocating cylinder
 During the extension stroke, the speed of
the piston is determined by the flow rate
out of the pump, and the area of the
blank-end of the piston.
vP Ab  Q pump , vP  Q pump Ab

 Assuming constant piston speed, and

resistive load on the piston, (load
resisting the extension), the pressure on
the rod end of the piston (gauge pressure)
is equal to the pressure loss in the return
line connecting the outlet port to the
pr  K pipeQ, laminar flow
tank.
pr  K pipeQ 2 , turbulent flow

f is the friction factor for the pipe. For fully

turbulent flow, f is a function of the pipe’s
 For a straight circular pipe, the pipe flow relative roughness. In the transition region, f is
K pipe  128 KLpipe
coefficient, Dis:, laminar flow
4
a function of the relative roughness and Re. It
K pipe  8 fL  2 D 5 , turbulent flow is determined from the Moody diagram.
 Flow and pressure analysis in the automatic
reciprocating cylinder
 The pressure on the blank end is
determined by the pressure on the rod
side and the load
pb Ab  pr Ar  Fload
pb  pr  Ar Ab   Fload Ab
Regenerative Circuit
 Regenerative Circuit
 One characteristic of the Fload
double acting cylinder
circuit is that the
extension speed is always
lower than the retraction
speed.
 Can you think with design
modification to the circuit
to make the extension
speed equal to the
retraction speed?
Regenerative Circuit
Fload Fload
 Regenerative Circuit
 A regenerative circuit is used to
speed up the extension speed of Fload
the piston in a double-acting
hydraulic cylinder. Note that the
pipelines to both ends of the
hydraulic cylinder are connected in
parallel, and that one of the ports
in 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. In this mode, fluid
from the pump bypasses the DCV
and enters the rod side of the
cylinder. Fluid in the blank side
drains back to the tank through the
DCV as the cylinder retracts
 Double Pump
Hydraulic System
 Double Pump Hydraulic System
 A high-pressure, low-flow pump
works in conjunction with a
low-pressure, high-flow pump.
A typical application is a sheet
metal punch where high force
and pressure requirements
occur during a short motion 0.00 Bar

portion of the hydraulic cylinder

when the punching operation
occurs.
 During the punching operation,
the cylinder travel is small, and
thus the flow-rate requirements Low Flow Pump High Flow Pump

are low. The circuit eliminates 24.00 LPM 630.00 LPM

the necessity of having a very

expensive high pressure, high
flow pump
 Double Pump Hydraulic System
 Before the punching operation
begins, the rapid extension of the
piston is provided by both pumps
operating at low pressure outlet
(pressure is determined by the load).
The flow of the high-flow pump goes
0.00 Bar
through the check valve to the
hydraulic cylinder.
 Near the end of the cylinder stroke
the punching operation begins and
the increased pressure opens the
unloading valve to unload the high- Low Flow Pump High Flow Pump
24.00 LPM 630.00 LPM
flow pump. The check valve protects
this pump from the high pressure
generated by the high-pressure
pump.
 Analysis of a Double Pump Circuit
 The gauge pressure on the rod end
of the piston is equal to the pb Ab  pr Ar  Fload
pressure loss in the return line pb  pr  Ar Ab   Fload Ab 0.00 Bar

connecting the outlet port to the

tank. pr ,ext  K pipeQ, laminar flow
pr ,ext  K pipeQ 2 , turbulent flow
Low Flow Pump High Flow Pump
24.00 LPM 630.00 LPM

 During the rapid extension, the flow  During the punching operation, the flow
rate is high and the rod-end rate is small, and the rod-end pressure is
pressure will be significant. The negligible. The blank-end pressure is
 pr ,ext  Apr b,ext
pb,extpressure,
blank-end  given by:
Ab is
determined by the punching load:
pb, punch  Fpunch Ab

 The pressure calculated above may  The pressure calculated above may be used
be used to determine the settings of to determine the settings of the pressure
the unloading valve, ps,uv . For relief valve, ps,rv . For example, we could
example, we could set it to be equal set it to be equal to 1.5 times pb,punxh
to 1.5 times pb,ext
Fail-Safe Circuits
 Protection from Inadvertent Cylinder
 Extension
The circuit utilizes a pilot operated check valve to prevent the cylinder
from falling in the event of hydraulic line rupture or pump failure. The
valve also provides protection in case someone inadvertently operates
the manual override on the pilot actuated directional control valve when
the pump is not operating.
 Protection from Inadvertent Cylinder
 Extension
This design also allows the upper directional control valve to be placed
at a distant location from the machine. The lines connected to the valve
are basically for sensing. Flow and pressure (high power lines) go
though the bottom DCV, which acts in a manner similar to relay.
 Protection from Inadvertent Cylinder
 Extension
This design also allows the upper directional control valve to be placed
at a distant location from the machine. The lines connected to the valve
are basically for sensing. Flow and pressure (high power lines) go
though the bottom DCV, which acts in a manner similar to relay.
 Fail Safe with Overload Protection
 Directional Control Valve 1 is Sequence
controlled by the pushbutton, Valve
three-way DCV2. If the
DCV 3
cylinder experiences excessive
resistance during its extension
stroke, the sequence valve
pilot actuates the overload
DCV 3.
DCV 2
 This drains the pilot line of
DCV1, causing it to return to its
spring-offset mode. If an
operator then tries to push
DCV 2, nothing happens unless
DCV 1
DCV3 is manually shifted to its
blocked port configuration.
Thus the system components
are protected from excessive
load during the extension
stroke.
 Two-Handed Safety System
 For the circuit to
extend, the
operator must
depress both
manually actuated
valves via the push
button.
 When the two
buttons are
depressed, the main
DCV is pilot-
actuated to extend
the cylinder. When
one of the
pushbuttons is
released, the
cylinder retracts.
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
Two-Handed Safety System
 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Variable displacement pump circuit

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Meter – in Circuit

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Meter – out Circuit

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Bleed – off Circuit

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Deceleration Circuit

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Feed speed varying circuit

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Multi Speed Circuit

Q1 : High Flow
Q1 Q2 : Low Flow

Q2

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Multi Speed Circuit
1 : Rapid Advance
2 : Medium Advance
1 3 : Slow Advance
UCF2-04

2 3

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 HYDRAULIC CIRCUITS
SPEED CONTROL CIRCUIT Multi Speed Circuit
Sol. 1 ON Low speed forward
Sol. 3 ON High speed forward

Sol. 3 OFF Speed decrease

Sol. 1 OFF Stop.

Sol. 1 Sol. 2 Sol. 3 Sol. 4

Sol. 2 ON Low speed reverse

Sol. 4 ON High speed reverse

M Sol. 4 OFF Speed decrease

Sol. 2 OFF Stop.
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 HYDRAULIC CIRCUITS
PRESSURE CONTROL CIRCUIT 2 Operating Pressure Circuit

1
2

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 HYDRAULIC CIRCUITS
PRESSURE CONTROL CIRCUIT Low Pressure Return Circuit

2
Pilot Relief
Valve

Main Relief
Valve
1

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 HYDRAULIC CIRCUITS
PRESSURE CONTROL CIRCUIT Decompression Circuit

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 HYDRAULIC CIRCUITS
UNLOADING CIRCUIT
Manual Unloading
To Circuit

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 HYDRAULIC CIRCUITS
UNLOADING CIRCUIT
Circuit using Accumulator

Detection of
Pressure by
Pressure Switch

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 HYDRAULIC CIRCUITS
UNLOADING CIRCUIT
Circuit using Accumulator

Detection of
Pressure by
Pilot Op. Relief
Valve
M

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 HYDRAULIC CIRCUITS
UNLOADING CIRCUIT ( Hi-Low Circuit ) Low Pressure Operation

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 HYDRAULIC CIRCUITS
UNLOADING CIRCUIT ( Hi-Low Circuit ) High Pressure Operation

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 HYDRAULIC CIRCUITS
SYNCHRONIZING CIRCUIT Series coupling circuit

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 HYDRAULIC CIRCUITS
SYNCHRONIZING CIRCUIT Mechanical Coupling

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 HYDRAULIC CIRCUITS
REGENERATIVE CIRCUIT - I Idle Condition

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 HYDRAULIC CIRCUITS
REGENERATIVE CIRCUIT - I Regenerative Advance

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 HYDRAULIC CIRCUITS
REGENERATIVE CIRCUIT - I Retraction

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 HYDRAULIC CIRCUITS
SEQUENCE CIRCUITS Electrically controlled circuit
1 2
Cylinder 1 Cylinder 2

3 4
LS-1 LS-2 LS-3

a b c d

Seq. Operation Signal Movemen

t
1 Push – ON Sol a Cyl. 1 M
2 LS - 2 ON Sol c Cyl. 2
3 LS - 3 ON Sol b Cyl. 1
4 LS - 1 ON Sol d Cyl. 2
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 HYDRAULIC CIRCUITS
SEQUENCE CIRCUITS Automatic control circuit
Small Load

Large Load

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 HYDRAULIC CIRCUITS
CLAMPING & SEQUENCING CIRCUIT Extending Clamp Cylinder

111
 HYDRAULIC CIRCUITS
CLAMPING & SEQUENCING CIRCUIT Extending Work Cylinder

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 HYDRAULIC CIRCUITS
CLAMPING & SEQUENCING CIRCUIT Limiting Max. Clamping Pr.

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 HYDRAULIC CIRCUITS
CLAMPING & SEQUENCING CIRCUIT Retracting Work Cylinder

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 HYDRAULIC CIRCUITS
CLAMPING & SEQUENCING CIRCUIT Retracting Clamp Cylinder

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 HYDRAULIC CIRCUITS
ACCUMULATOR UNLOADING CIRCUIT Charging

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 HYDRAULIC CIRCUITS
ACCUMULATOR UNLOADING CIRCUIT Unloading

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 HYDRAULIC CIRCUITS
ACCUMULATOR UNLOADING CIRCUIT Supply from Accumulator

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 HYDRAULIC CIRCUITS
ACCUMULATOR CIRCUITS Power saving circuit
Starter
motor

Starting
circuit for a
diesel
engine.

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 HYDRAULIC CIRCUITS
ACCUMULATOR CIRCUITS Pressure holding
( leakage compensation )

Vice

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 HYDRAULIC CIRCUITS
ACCUMULATOR CIRCUITS Safety Device

Safety
device in
a Rolling
Mill

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 HYDRAULIC CIRCUITS
ACCUMULATOR CIRCUITS Surge pressure reducing circuit

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 HYDRAULIC CIRCUITS
ACCUMULATOR CIRCUITS Pump capacity reducing circuit

M
Low
Pressure High Pressure
Pump Pump
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 HYDRAULIC CIRCUITS
COLLECTION OF DATA FOR CIRCUIT DESIGN
 CYLINDER DETAILS
SINGLE ACTING OR DOUBLE ACTING ?
HOW MANY CYLINDERS ?
SEQUENCE OF CYLINDER MOVEMENT
( ONE AFTER OTHER OR ALMOST TOGETHER )
FUNCTION OF THE CYLINDER ( Eg., Clamping, Drilling )
MACHINE TO WHICH THESE CYLINDERS GO ( Eg., Grinding M/c. )
BORE SIZE & ROD SIZE OF THE CYLINDER
STROKE LENGTH OF THE CYLINDER
MANUAL OR SOLENOID OPERATED MOVEMENT ?
FORCE ACTING ON THE CYLINDER
SPEED OF MOVEMENT REQUIRED
SINGLE SPEED / DOUBLE SPEED / MULTI SPEED ?
LOAD REQUIREMENTS
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 HYDRAULIC CIRCUITS
COLLECTION OF DATA FOR CIRCUIT DESIGN

 OTHER DETAILS

LOCATION OF SYSTEM / EQUIPMENT / ACTUATOR

( Eg. Distance between Power Unit to the Actuator )

LIMITATIONS OF OPERATION ( Eg. Medium, Environment, Space )

AVAILABILITY OF POWER SOURCE & DETAILS ( Eg. AC / DC )

TYPE OF COOLING REQUIRED

SAFETY MEASURES NEEDED

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 HYDRAULIC CIRCUITS

UNDERSTANDING
HYDRAULIC CIRCUITS & HYDRAULIC POWER PACKS

BEGIN WITH THE END

ACTUATORS

HYDRAULIC CYLINDERS HYDRAULIC MOTORS

( LINEAR ACTUATORS ) ( ROTARY ACTUATORS )

126
 HYDRAULIC CIRCUITS
A good hydraulic circuit design can be made only when the
parameters influencing the feed drive are clearly understood.
TYPES OF SLIDE
• VERTICAL
• HORIZONTAL
• INCLINED
TYPES OF MACHINING
• ROUGH MACHINING
• FINE MACHINING

127
 HYDRAULIC CIRCUITS

NORMAL WORKING PRESSURES FOR VARIOUS SYSTEMS

FIELD OF Pressure ( Kg / Cm2 )

APPLICATION AVERAGE
RANGE

MOBILE 70 ~ 300 150

SHIPS ( MARINE ) 40 ~ 250 90
MACHINE TOOL 20 ~ 70 33
FORGES 140 ~ 250 195
INJECTION MOULDING M/c 70 ~ 210 130
INDUSTRIAL ROBOT 5 ~ 140 64

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 HYDRAULIC CYLINDERS
SELECTION OF AN ACTUATOR
F1
d

D

AREA A1 AREA A2
F2
PRESSURE = OUTPUT FORCE
EFFECTIVE PISTON AREA
P= F Kg
A Cm2

129
 HYDRAULIC CIRCUITS
SELECTION OF AN ACTUATOR
Eg. : Pressure = 50 Kg / Cm2
Force required = 4000 Kgs. ( 4 Ton )

P= F A= F
Or
A P

= 4000 Kg = 80 Cm2
50 Kg / Cm2

A =  x D2 ( In this Example A = 80 Cm2 )

4
80 =  x D2
4 D = 100 mm
Use  100 mm Bore Cylinder
130
 HYDRAULIC CIRCUITS
SELECTION OF AN ACTUATOR

STANDARD BORE SIZES OF CYLINDERS ( mm )

32 40 50 63 80 100 125 140 150 160 180 200 220 250 300

TO CALCULATE THE FLOW “ Q”

Q=AxV
Q = Flow in Cm3 / min. ( Divide by 1000 to get flow in LPM )
A = Area in Cm2
V = Velocity in Cm / min

131
 HYDRAULIC CIRCUITS
TO CALCULATE THE MOTOR POWER

MOTOR POWER (KW) = PxQ

612 x O

P = Pressure in Kg / Cm2
Q = Flow in LPM
O = Pumps Overall Efficiency ( Eg. 85 %  0.85 )

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 HYDRAULIC CIRCUITS
Heat Generation in a Hydraulic System
SOURCE : Oil Pump

Oil pumps exhaust a large portion of its shaft-input power to perform

an effective task ( Pump output pressure, pump output flow ), while
the rest turns into heat without doing any work.

H1 = Li x ( 100 - O ) x 860
100

H1 = Heat generated from the Pump ( Kcal / Hr )

Li = Pump input power ( KW )
O = Pump overall efficiency ( % )

133
 HYDRAULIC CIRCUITS
Heat Generation in a Hydraulic System
SOURCE : Orifices

When pressurised fluid flows through throttle parts at a certain

pressure, the pressure drop is converted into heat ( H2) . Especially
considerable heat will be produced when the pressurised fluid is
released to tank through the Relief valve.

H2 = 10 x 60 x P x Q
427
H2 = Heat generated ( Kcal / Hr )
P = Differential pressure across an orifice. ( Kg / Cm2 ).
In case of relief valves the set pressure shall be the
differential pressure.
Q = Flow through the orifice ( Lpm )
134
 HYDRAULIC CIRCUITS
HEAT GENERATION
Load Normal Heat Rise
Pr. 20 Kg/Cm2
1 Kw = 860 Kcal / Hr
40 LPM PQ Kw =
Set 612
Pr. 100 Kg/Cm2
PQ X 860 Kcal / Hr
612
60 LPM
= 100 x 60 x 860
612
= 8431 Kcal / Hr
Pump
100 LPM
M

135
 HYDRAULIC CIRCUITS
HEAT GENERATION
With Load
Load Sensing Heat Rise
Pr. 20 Kg/Cm2
1 Kw = 860 Kcal / Hr
40 LPM PQ Kw =
612

Set PQ X 860 Kcal / Hr

Pr. 100 Kg/Cm2 612
= 20 x 60 x 860
60 LPM 612
= 1686 Kcal / Hr
Pump
100 LPM M

136
 HYDRAULIC CIRCUITS
HEAT GENERATION
With Load
Load Sensing
Pr. 20 Kg/Cm2

40 LPM
Set
Pr. 100 Kg/Cm2

60 LPM

M
Pump
100 LPM

137
 HYDRAULIC CIRCUITS
Heat dissipation from a Hydraulic System
SOURCES : Reservoir, Tubings, Components

The dissipated heat ( H3 ) from the surface of the reservoir -

H3 = K x A x ( t1 – t2 ) ( Kcal / Hr )

K = Coefficient of heat dissipation. ( 7 – 9 Kcal / Hr.c.m2 )

A = Effective Area of the Reservoir. ( m2 )
t1 = Oil Temperature (  C )
t2 = Room Temperature (  C )

In very well ventilated circumstances we can estimate the value of

the Heat transfer coefficient “ K” around 15 Kcal / Hr. C.m2

138
 HYDRAULIC CIRCUITS
Heat dissipation from a Hydraulic System
A = Effective Area of the Reservoir. ( m2 )

H = 450

L = 1000 B = 700
A = L x B x H
= 2[LxH] + 2[BxH] + [LxB]
= 2 [ 1000 x 450 ] + 2 [ 700 x 450 ] + [ 1000 x 700 ]
= 2 [ 1 x 0.45 ] + 2 [ 0.7 x 0.45 ] + [ 1 x 0.7 ]
= 0.9 + 0.63 + 0.7
= 2.23 m2
H3 = K x A x ( t1 – t2 ) ( Kcal / Hr )
139
 HYDRAULIC CIRCUITS
Oil Temperature
At Equilibrium Condition
The oil temperature accelerates the heat transfer as it rises, and
reaches an equilibrium state of thermal relationship H1 + H2 = H3
The equilibrium oil temperature -
t1 = H1 + H2 + t2
KA

140
 HYDRAULIC CIRCUITS
Oil Temperature
When the temperature is rising
The thermal relationship H1 + H2 > H3 then the oil temperature “t”
at a time “ T” is given by –

- KA T
t = H 1 + H2 C + t2
KA 1 – e

C = Heat capacity of the Reservoir ( Cm3 )

C = v xrxS
Where
v = Reservoir capacity. ( cm3 )
r = Specific gravity of oil ( 0.86 x 10 –3
Kgf / Cm3 )
S = Specific heat of oil ( 0.45 Kcal / Kg C )
T = Time ( Hr. )
141
 HYDRAULIC CIRCUITS

MODULAR VALVES

Features

STACKABLE UNITS
– MAINTENANCE AND SYSTEM CHECK UP MADE EASY.
INSTALLATION AND MOUNTING SPACE MINIMISED.
PIPING ELIMINATED
- OIL LEAKS, VIBRATION AND NOISE CAUSED BY
PIPING MINIMISED.
NO SPECIAL SKILL REQUIRED FOR ASSEMBLY AND ANY
ADDITION OR ALTERATION OF THE HYDRAULIC CIRCUIT
CAN BE MADE QUICKLY AND EASILY.
142
 HYDRAULIC CIRCUITS
Caution in the Selection of Valves and Circuit designing

( INCORRECT ) ( CORRECT )

Solenoid Operated
S o l e n o i d O p e r a te d
Directional valve
D ir e c ti o n a l V a lv e

Pilot Operated Check

Modular valve
(for “A” & “B” Lines)

Reducing Modular
valve
( for “B” line )
P T B A P T B A

143
 HYDRAULIC CIRCUITS
Caution in the Selection of Valves and Circuit designing

( INCORRECT ) ( CORRECT )

Solenoid Operated
S o l e n o i d valve
Directional O p e r a te d
D ir e c ti o n a l V a lv e

Throttle and Check

Modular valve
(for “A” & “B” Lines
Meter-out )

Pilot Operated Check

Modular valve
(for “A” & “B” Lines)
P T B A P T B A

144
 HYDRAULIC CIRCUITS
Caution in the Selection of Valves and Circuit designing

( INCORRECT ) ( CORRECT )

Solenoid Operated
Directional
S o l e n o i d valve
O p e r a te d
D i r e c t io n a l V a lv e
Throttle and Check
Modular valve
(for “A” & “B” Lines
Meter-out )

Brake Modular
valve
P T B A P T B A

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HYDRAULIC CIRCUITS

146
HYDRAULIC CIRCUITS

147
HYDRAULIC CIRCUITS

Hyd. Power unit for

Multi Spindle Drilling M/c.

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Logic Valves

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Logic Valves - Features

MULTIFUNCTION PERFORMANCE IN TERMS OF DIRECTION,

FLOW AND PRESSURE CAN BE OBTAINED BY COMBINING
ELEMENTS AND COVERS.

POPPET TYPE ELEMENTS VIRTUALLY ELIMINATE INTERNAL

LEAKAGE AND HYDRAULIC LOCKING. BECAUSE THERE ARE
NO OVERLAPS, RESPONSE TIMES ARE VERY HIGH,
PERMITTING HIGH-SPEED SHIFTING.

FOR HIGH PRESSURE, LARGE CAPACITY SYSTEMS,

OPTIMUM PERFORMANCE IS ACHIEVED WITH LOW PRESSURE
LOSSES.

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Logic Valves - Features

SINCE THE LOGIC VALVES ARE DIRECTLY INCORPORATED

IN CAVITIES PROVIDED IN BLOCKS, THE SYSTEM IS FREE
FROM PROBLEMS RELATED TO PIPING SUCH AS OIL LEAKAGE,
VIBRATION AND NOISE, AND HIGHER RELIABILITY IS
ACHIEVED.

MULTI-FUNCTION LOGIC VALVES PERMIT COMPACT

INTEGRATED HYDRAULIC SYSTEMS WHICH REDUCE MANIFOLD
DIMENSIONS AND MASS AND ACHIEVE LOWER COST
CONVENTIONAL TYPES.

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Logic Valves - Features

A
F u n c t i o n s , w o r k i n g a r e a r a t io s a n d fe a t u r e s
W o r k ing ar e a ra tio
F u n c ti o n G r a p h ic S y m b o ls F e a tu re s
(A A : A B)
P o pp e t s hap e
W i th o u t c u s h i o n ( L D / L D S -  -  ) : h i g h - s p e e d s h i f t
/ W i t h c u s h i o n ( L D /L D S -  -  - S ) : S h o c k l e s s s h i f t
D i r e c ti o n N o le a k ag e b e tw e e n p o rt A a nd B
X
B
F lo w A to B a n d B to A a re p o ss ib le
A R e s p o n s e t i m e a n d s h o c k c a n b e a d j u s t e d b y o r i f i c e s e l e c ti o n .
(2 : 1 )
P o pp e t s hap e
W i t h c u s h i o n ( L D -  -  - S - 1 / 2 / 3 ) : f l o w c o n tr o l .
D i r e c ti o n N o le a k ag e b e tw e e n p o rt A a nd B
a n d F lo w X
B F lo w A to B o n ly is p o ss ib le .
A R e s p o n s e t i m e a n d s h o c k c a n b e a d j u s t e d b y o r i f i c e s e l e c ti o n .

R e m o te a n d u n lo a d i n g c o n t r o l i s p o s s i b l e w i t h v e n t c i r c u i t ( L B -  -  ) .
R e lie f Y (2 4 : 1 ) T w o o r th r e e p r e s s u r e c o n t r o ls a r e p o s s i b le i n c o m b i n a t io n o f s o l e n o i d
X
B o p e r a t e d d i r e c ti o n a l v a l v e a n d p i l o t r e l i e f v a l v e ( L B S -  -  ) .
A

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Selection of accumulator capacity.
There are many chances to use accumulator as a source of
energy.
To select the capacity of accumulator, We must know:
(1) Required oil discharge amount: liters.
(2) Max. operating pressure: P3 Kgf / Cm2.
(3) Min. operating pressure : P2 Kgf / Cm2.
(4) Gas charge pressure : P1 Kgf / Cm2.
P1  P2 (0.85 ~ 0.9)
(5) Charging time, discharge time
Especially for discharge time
Incase T > 1 min: use isothermal change.
T < 1 min: use adiabatic change.
From these required specification we can calculate the required
vol. of accumulator.
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CASE STUDY - I : CNC Drilling Machine

Data Available :
1. CYLINDER SPECIFICATION :
Clamping -  125 x  50 x 20 Stroke
Drilling -  63 x  35 x 100 Stroke
2. LOAD OR FORCE ACTING ON THE CYLINDER
Clamping - 400 Kgf
Drilling - 250 Kgf
3. SPEED OF ACTUATORS
Clamping - 1.5 M / min.
Drilling - 0.1 M / min.

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CASE STUDY – I : CNC Drilling Machine
1 ) Pressure required for clamping “ P1 ”
A =  x D2
P1 = F = 400
4
A 122.7
A =  x 12.5 x 12.5

= 3.3 Kg / Cm2 4
= 122.7 Cm2

2 ) Pressure required for drilling “ P2 ” A =  x D2

P2 = F = 250 4
A 31.2 A =  x 6.3 x 6.3
4
= 8 Kg / Cm 2

= 31.2 Cm2

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CASE STUDY – I : CNC Drilling Machine
3 ) Flow required for clamping “ Q1 ”
A =  x D2
Q 1= A x V 4
= 122.7 x 1.5 x 100 Cm3 / min A =  x 12.5 x 12.5

= 18405 Cm3 / min

4
= 18.4 LPM = 122.7 Cm2

4 ) Flow required for drilling “ Q2 ” A =  x D2

Q 2= A x V 4
A =  x 6.3 x 6.3
= 31.2 x 0.1 x 100 Cm / min
3
4
= 312 Cm3 / min
= 31.2 Cm2
= 0.31 LPM

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CASE STUDY – I : CNC Drilling Machine
5 ) Electric Motor Power

MOTOR POWER (KW) = PxQ 8 x 18.4 = 0.28 KW

612 x O 612 x 0.85 (0.38 HP)

1 hp = 0.746 KW

6 ) Tank Size - ( General Thumb Rule )

For Vane & Gear Pumps = 4 ~ 5 times of System Flow
For Piston Pumps = 2 ~ 3 times of System Flow

7 ) Maximum Pressure to be considered = 8 Kg / Cm2

Maximum Flow to be considered = 18.4 LPM
Electric Motor Power = 0.38 say 0.5 HP
Tank Capacity = 18.4 x 4 = 73.6 say 75 ltrs
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4
SEQUENCE CIRCUITS 1
Clamp
Circuit using
Sequence
3
Valve 2 Drill
1

SEQUENCE
VALVE 2
4

SEQUENCE VALVE

Sequence of Sequence of Flow

Operation
1 - CLAMPING
1 2 3 4

2 - DRILLING
M
3 - DRILL
RETURN 4 - DE
CLAMP
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