HYDRAULICS AND PNEUMATICS LAB: AMEE 310

LABORATORY HANDOUT

EXPERIMENT 3: CYLINDERS IN SERIES

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Cylinders In Series

CYLINDERS SERIES

EXERCISE OBJECTIVE

To describe the operation of a series circuit;

To cause two cylinders to start and stop at the same time by connecting
them in series.
To demonstrate pressure intensification in a series circuit.

DISCUSSION

Cylinders in series

In some hydraulic applications, it is necessary for two cylinders to work together

in unison. For example, two cylinders may be required to start and stop
extending at the same time. Cylinders operating in this manner are said to be
synchronized.

One method to synchronize two cylinders consists in connecting them in series,

so that the discharge flow from one cylinder serves as the input flow to the
second cylinder.

Figure 3-6 shows two cylinders connected in series. The rod end of one cylinder
is connected to the cap end of the second cylinder. With this circuit, neither
cylinder can move unless the other is also moving.

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Figure 3-6. Cylinders connected in series.

Shifting the lever of the directional valve in Figure 3-6 will cause the cylinders to
start and stop at the same time. If the cylinders are of the same size and stroke,
however, cylinder 2 (downstream cylinder) will extend slower, and It will not
extend completely since the flow out of the rod end of cylinder 1 (upstream
cylinder) will be less than the flow entering the cap end of cylinder 1.

If the two cylinders are of the same size, the total force of the two cylinders in
series is equal to the system pressure multiplied by the area of one of the piston.
Differences0 in cylinder size, however, will cause considerable variation.

Pressure intensification in a series circuit

Intensification of the system pressure will occur in a series circuit if the flow from
the rod end of the upstream cylinder is blocked severely restricted as by a
heavy load on the downstream cylinder.

Figure 3-7 shows an example. The cylinders in this figure have the same size as
the two cylinders supplied with your Hydraulics Trainer. The input force exerted
on the full piston area of the upstream cylinder is 1775 . Since the flow from the
rod end of this cylinder is partially blocked by the heavy load on the downstream
cylinder, the pressure at the rod end of the upstream cylinder will rise until the
force applied on the annular piston area of the upstream cylinder equals the input

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force of 1775 .

Figure 3-7. Pressure intensification in a series circuit.

Due to the difference in exposure area between the full and annular piston area,
the pressure at the rod end of the upstream cylinder will intensify by a factor
equal to the ratio of the full piston area to the annular piston area, A 1/Aa, resulting
in a pressure of 5763 kPa at the cap end of the downstream cylinder, and in a
force of 6570 at the output load. Notice that the intensification ratio A 1/Aa will
hold as long as there is no load on the upstream cylinder.

REFERENCE TERIAL

For detailed information on cylinder synchronization, refer to the chapter entitled

Check Valves, Accumulators and Cylinders in the Parker-Hannifin's manual
Industrial Hydraulic Technology.

Procedure summary

In the first part of the exercise, you will connect two cylinders in series with a

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loading device to the upstream cylinder. The loading device will be a flow control
valve. You will gradually increase the load on the upstream cylinder, while noting
the effect a change in load has on the synchronization of the cylinders, along with
the pressures applied to both cylinders.

In the second part of the exercise, you will connect the loading device to the
downstream cylinder. You will repeat the manipulations performed in the first part
of the exercise in order to observe the effect a change in load position has on the
operation of the series circuit.

QUI REQUIRED

Refer to the Equipment Utilization Chart, in Appendix of this manual, to obtain

the list of equipment required to perform this exercise.

PROCEDURE

Series circuit with load on the upstream cylinder

1. Connect the circuit shown in Figure 3-8. In this circuit, the Flow Control
Valve will act as a loading device on the upstream cylinder [2.54-cm (1-)
bore).

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Figure 3-8. Series circuit with

load on the upstream Note: If the rods of the 2.54-cm (1-) and 3.81-cm cylinder.

(1.5-) bore cylinders are not fully retracted, do

not connect the circuit in Figure 3-8. Instead,
retract the rod of each cylinder hydraulically by
using the cylinder actuation circuit shown in Figure
2-10. When both rods are retracted, connect the
circuit shown Figure 3-8.

2. Before starting the Power Unit, perform the following start-up procedure:

a. Make sure the hoses are firmly connected.

b. Check the level of the oil in the reservoir. Add oil if required.
c. Put on safety glasses.
d. Make sure the power switch on the Power Unit is 5et to the OFF
position.
e. Plug the Power Unit line cord into an ac outlet.
f. Open the Relief Valve completely (turn knob fully
counterclockwise).

3. Turn on the Power Unit

4. Open the Flow Control Valve completely (turn knob fully counterclockwise)
so that no load is placed on the upstream cylinder.

5. Move the lever of the directional valve toward the valve body to extend
both cylinders. While keeping the valve lever shifted, turn the Relief Valve
adjustment knob clockwise until the circuit pressure at gauge is 1720
kPa (250 psi). Retract the cylinders by moving the valve lever outward
from the valve body.

6. While observing the cylinders, move the lever of the directional valve

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toward the valve body to extend their rod. D0 the cylinders start and stop
at the same time? Does the downstream cylinder [3.81-cm (1.5-in) bore]
extend fully? Explain.

Answer:

7. Retract the cylinders.

8. Now extend and then retract the cylinders again and observe the pressure
readings at gauges and as the cylinders are extending. Record these
pressures in the "NO-LOAD" row of Table 3-6.

PRESSURE
LOAD CONDITION GAUGE A (UPSTREAM GAUGE B (DOWNSTREAM
CYLINDER) CYLINDER)
NO-LOAD
MEDIUM LOAD
HEAVY LOAD
STALL

Table 3-6. Circuit pressures with load on the upstream cylinder.

9. Put a medium load on the upstream cylinder. To do , close the Flow

Control Valve completely (turn knob fully clockwise), then open it 1 turn.

10. Extend and then retract the cylinders. 00 they start and stop at the same
time?

Yes
11. Extend and then retract the cylinders and observe the pressure readings

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at gauges and as the cylinders are extending. Record these pressures

in the "MEDIUM LD" row of Table 3-6.

12. Put a heavy load on the upstream cylinder. do so, close the Flow
Control Valve completely (turn knob fully clockwise), then open it turn.

13. Extend and then retract the cylinders. 00 they start and stop at the same
time?

Yes

14. From your observations, does a change in load affect) the synchronization
of the two cylinders? Explain why.

Answer:

15. Extend and then retract the cylinders and observe the pressure readings
at gauges and as the cylinders are extending. Record these pressures
in the 'V LD" row of Table 3-6.

16. Close the Flow Control Valve completely (turn knob fully clockwise) so that
the upstream cylinder will stall completely.

17. Attempt to extend the cylinders, while observing the pressure readings at
gauges and . Record these pressures in the "SALL" row of Table 3-6.

18. Turn off the Power Unit. D0 not modify the Relief Valve pressure setting.

19. According to Table 3-6, did the pressure required to extend the down-
stream cylinder remain approximately constant when the various loads
were placed on the upstream cylinder? Why?

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Answer:

20. Why did the pressure at gauge drop when the load stalled the cylinders?

Answer:

21. If you were asked to modify the bore size of the upstream cylinder to allow
both cylinder5 to complete their full stroke (10.16 cm/4 in) at the same
time, what bore size would you select?

Note: Keep the same rod size (1.59 cm/O.625 in)

for the upstream cylinder.

Series circuit with load on the downstream cylinder = 1.62in

22. Modify your circuit connections in order to place the loading device (Flow
Control Valve) on the downstream cylinder [3.81-cm (1.5-) bore), as
Figure 3-9 shows.

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Figure 3-9. Series circuit with Load on the downstream cylinder.

23. Turn on the Power Unit.

24. Open the Flow Control Valve completely (turn knob fully counterclockwise)
so that no load is placed on the downstream cylinder.

25. Extend the cylinders. Do they still start and stop at the same time? Explain
why.

Answer:

26. Retract the cylinders.

27. Extend and then retract the cylinders and observe the pressure readings
at gauges and as the cylinders are extending. Record these pressure
in the "NO-LOAD" row of Table 3-7.

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PRESSURE
LOAD CONDITION GAUGE A (UPSTREAM GAUGE B (DOWNSTREAM
CYLINDER) CYLINDER)
NO-LOAD
MEDIUM LOAD
HEAVY LOAD
STALL

Table 3-7. Circuit pressures with load on the downstream cylinder.

28. Put a medium load on the downstream cylinder. To do so, close the Flow
Control Valve completely (turn knob fully clockwise), then open it 1 turn.

29. Extend and then retract the cylinders and observe the pressure readings
at gauges and as the cylinders are extending. Record these pressures
in the "MEDIUM L" row of Table 3-7.

30. Put a heavy load on the downstream cylinder. To do so, close the Flow
Control Valve completely (turn knob fully clockwise), then open it turn.

31. Extend and then retract the cylinders and observe the pressure readings
at gauges and as the cylinders are extending. Record these pressures
in the 'V LOAD" row of Table 3-7.

32. Close the Flow Control Valve completely (turn knob fully clockwise) so that
the downstream cylinder will stall.

33. Attempt to extend the cylinders while observing the pressure readings at
gauges and . Record these pressures in the "STALL" row of Table 3-7.

34. Turn off the Power Unit Open the Relief Valve completely (turn knob fully
counterclockwise).

35. According to Table 3-7, did the pressures at gauge and increase as
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the load on the downstream cylinder was increased? Why?

Answer:

36. According to Table 3-7, is the ratio of gauge to gauge pressure

approximately equal to the ratio of annular to full piston area (A 1/Aa) of the
upstream cylinder for the MEDIUM, HEAVY, and SALL load conditions? If
so, explain why.

Answer:

37. Explain the reason why pressure intensification can occur in a series
circuit.

Answer:

38. Disconnect the line cord from the wall outlet, then disconnect a/l hoses.
Wipe off any hydraulic oil residue.

39. Remove all components from the work surface and wipe off any hydraulic
oil residue. Return all components to their storage location.

40. Clean up any hydraulic oil from the floor and from the trainer. Properly
dispose of any paper towels and rags used to clean up oil.

CONCLUSION

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REVIEW QUESTIONS

1. What is meant by "cylinder synchronization"?

Answer:

2. In a series circuit, can the upstream cylinder be extended after the

downstream cylinder has completed its movement? Why?

Answer:

3. In a series circuit where the two cylinders are of the same size and stroke,
will both cylinders extend completely? Explain why.

Answer:

4. In a series circuit where a heavy load is attached on the downstream

cylinder, by which amount will the input pressure intensify if the upstream
cylinder is a 3.81-cm (1.5-in) bore 1.59-cm (O.625-in) rod cylinder?

Answer:

5. Calculate the theoretical force output in the circuit of Figure 3-10.

Answer:

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Figure 3-10. Circuit for review question 5.

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