Basic circuit diagrams f | | Applications | ! — ! : 1. The elreuit diagram f The circuit diagram is the technical representation of a control installa tion, oF a drive assembly, using the Graphical symbols in accordance with the DINISO 1219 standard. For reasons of clarity, the circuit diagram should be drawn without con- sideration for the actual arrangement i ff the components in the instalation, 4 It should also be drawn trom the ] bottom of the page to the top of the page and corresponding to the direc: tion of eneray flow. asa boca recon cntl iectesertarrertenepenat Siatptatec et coedon eek Valves with @ number of eifferent switched positions should be drawn in their basic position |e. that position taken up by the Moving parts of the valve when current and pressure Is not applied, or when the valve is not actuated. I necessary, the initial post tion can be shown corresponding te the start conditions, In the case of combined electro hydraulic systems, separate circuit ‘dagrams are to be drawnup for the ‘electrical and for the hydraulle ‘controls. Signal alemonts such as limit | ‘switches or pressure switches are to be shown in both circuit diagrams, as are solenoid valves. The interaction between the two systems is 10 be | ‘shown in functional diagrams. ‘he hysrauie cet diagram can be Supplemented by data concerning | bumps, einere and hydraute | oto setting pressures pipe and Ine eimensione, power ata and rota tonal poed ts 210 Bosch hydraulics, basic circuit diagrams/applications 10080-2320 de by 5) 4| Se [ S PALS Sa © oH H@ ® . 5 & eaosch hydraulics, basic circuit diagrams/applications In order to protect the individual com- ponents and the lines from excess~ pressure loading, and to prevent them Bursting, itis necessary that the pres- sure is limited in all hydraulic installa- tions, The pressure-elie vaive is used for this purpose and is fitted directly alter (downstream of) the pump in the parallel ine, A pressure gauge is focated in the feed line. Maximum pressure only occurs when the load Feaches i limit, eg. when a cylinder is, extended to its end stop. It a variable-capacity pump with pres- sure compensator is fitted instead of ‘a constant-eapacity pump, the system must be safeguarded by a pressure feliet valve as well. Normally, this valve does not respond and is to be set to.a pressure considerably higher than that of the pressure compensa tor. when large masses are braked due to the sudden closure of a directional- ‘control valve, pressures occur in the Toad lines which are not safeguarded against by the pressure-relief valve rnext to the pump. The same applies to shocks and blows at the cylinder when the directional-control valve is, closed Ht may be necessary, under certain ‘eircumstances, to fit additional pres sure-reliet valves in the load line in Order to safeguard against overload ‘Their drain can go to the tank or to the opposite line. Loss of oil can be made up for by a suction valve. 3, Pump discharge ifthe load does not need any pressu- ‘ized oll, the delivery flow is to be Girected back to the tank (as far as possiole at zero pressure), or delivery is to be stopped completely. Ifthe oll is led-off through the pressure-relia! valve while under pressure, this ‘means that the drive powar is con: verted into heat loss, in other words a waste of energy. b 211 oa J | - Ps=p; + 10 bar Its only worthwhile to switet off the pump drive campletely if the machine is to be shut down or stopped for a ‘considerable period of time. In this ‘connection, It should be remembered that tne installation is not immediately ready for operation upon being Switched on again. For instance, the oil temperature can have dropped too far, oF the pump can only be started if the circuit is pressureless. If the pauses are relativaly shor, Its recommended that pump drive is con tinued and that the losses aro avoided as follows:ee toy we 212 Bosch hydraulics, basic circuit diagrams/applications 3.1 Pressureless circulation ‘The flow delivered by a constant- capacity pump is led off to the tank at ‘oto pressure (or at least at minimum pressure). A slight amount of eneray Foss occurs due to the residual friction, ‘against which the oil is circulated Pressureless circulation can be ettec- ted as follows: — by means of a connection PT in the directional-control vaive for the ‘contro! of direction —by means ofa directional-contro! valve specially fitted for this purpose by using a small-sized directional- control valve to relieve a pilot: controlled pressure-eliet valve —by way of a neutral circulation through a directional-control valve block (mobile applications) ‘With the solutions deatt with up to now, the system pressure collapses ‘as soon as the pump is switched over to pressurolass circulation. I the pres: sure must be maintained though, for clamping functions for instance, the following methods can be applied ~ the pressure Is held constant by means of an accumulator the main pump is relioved by a Switchroff valve and the pressure is ‘maintained by a small auxiiary pumpBosch hydraulics, basic circuit diagrams/applicat 9.2 Variable-capacity pump with pressure compensator ‘The variable-capacity pump is thrott- led back, that is it stops delivering, as soon as the pressure line is closed and the pressure set at tho pressure ‘compensator has been reached. Advantage: The pressure Is held constant Disadvantage: The leakage losses in the pump make it necessary to per- manently compensate {or efficiency losses in ‘the pump itself whilst this is running, It tis not required that the pressure is ‘maintained, the pilot-controlied pres sure compensators can be switched off. In this manner, its possible to further reduce the power loss in tho pump. This method is algo used in order to facilitate the starting of electric motors, ee pas i law) te 2 ae | Working point when the pressure tne | isetoses 1 cape a I | axed bs | | \ | zh Ly a Working point with the pressure Compensator switched off214 Bosch hydraulics, basic circuit diagrams/applications ch 4. Application of directionaleeomtpel | qe valves Ditectional-control valves are usually used for controlling the direction, as wellas the start or stop, of a cylinder (or hydraulic motor. In the following, a number of such | basic circuits are dealt with: ~ Control false and lower ofa Ioeded yinder Hoe, 22 dec: Nonaontol valves used together witha nonotum ati on Boslblo tatoo” nan ina Imelatepeltion I the pump I tchad ot ' a areal 1 —Contro of “aise” and lower” of a loaded cylinder by means of -_ re 312 drectional-contral valve gr ae ae a a a | Control of direction, without (rt ae > See eee Intermediate stop, by means of an electrically operated 4/2 direct nal-control valve with spring return The eylinder piston returns to Its ] Initial position when no electrical ower is applied to the solenoid and itis not energised (power failure),Bosch hydraulics, ba Control of direction, with inter- modiate stop, by means af an elec- ‘tically operated 4/3 directional- control valve. circuit diagrams/applications oO | rll ADESIPIRS Cylinder piston is counter-balanced at the intermediate stop. Caution: leakage takos place from A 10 (the differential cylinder In the intermediate stop position, the oylinder piston can be shifted by external forces, pols Reece oR sae Circulation without pressure in the ‘case of a ditectionalcontrol valve in its centre position. Cylinaer piston is counter-balancea, Sor ia | sel, wal al fs ale AIS CEES \ Circulation without pressure in the | case of a directional-control valve Ian intermediate position, the | cylinder piston can be shied, Caution: pressure build-up at 1. a é216 Bosch hydraulics, basic circuit diagram: s/applications 7 < d ‘te J » 5. Speed control with flow-control valves 5.1. Flow-control valves with and without by-pass check valve Generally, flow can take place through simple throttles in both direc: tions. Such throttles are usually located directly next to the load, and are effective for both directions of movement. It must be taken into ‘account that (in application ‘a") the throttle is effective both inthe inlet to the cylinder (primary side) and in the outlet from the cylinder (secondary side). Even though the same piston area applies in both directions though, different shift speeds resut, depending upon direction, as a result ‘of the differing pressure drops caused by the piston-area ratio inside the eylinder. Ifthe speed is only to be controled in one ditection of shit, throttling check: valves are fitted which are only effec tive in one direction (application *b") Fitting one of those valves in each of the cylinder lines makes it possible to.control both directions of shift Independently of each other (applica tion "e"), ‘Speed control using throttles is dependent upon the laad. Ifthe Influence of the load is to be compen: sated for, flow-control valves ara to be fitted. These are always only ettec- tive in one direction, and are usually combined with a by-pass check valve ‘The following examples refer mainly to control circuits using flow-contral valves.Bosch hydraulics, basic circuit diagrams/applications 52 Meter-in and meter-out circuits difference in the effective cylinder The diagram below shows 4 different piston areas must be taken into € arrangements using 2-way flow-co! trol valves. in applications “a” and account. Furthermore, the accuracy of the speed control is adversely the flow-contral valve cirouit is” —_affactad by leakage in the directional- located in the primary side (meter-in. control valve and by the relatively circuit), and in "c" and “ secondary side (meter-out circuit). ‘When the flow-contral vaive is located in one of the lines between the cylinder and the directional= control vaive ("b" and *e"), it only controls the speed in one direction. When fitted in the inlet, or in the out: let from the directional-control valve (Cat and *c°, it controls the speed in both directions. Here though, the itisin the large compression volumes. | | wantin eee Ke = = ss j TS 4 , | eas ee} » AUER, i | bw ioe Po ih ty va i € 1 '218 Bosch hydraulics, ba: 5.2.1 Advantages and disadvantages of the meter-in circuit The diagram on the right shows the flow-control valve located in the primary line (meter-in circuit) directly before the load, The following pressu: 10s are measured at 3 ditferent points: Pressure gauge 1: registers the pres Ure Pras deter ‘mined by the pres: sure-oliet valve of pressure compen: Ssator of the pump. With the throttle control itis pre: sumed that excess flow is deliveres by the constant capacity pump, and that this is drained: off through the prossure-roliot valve (power loss}, ‘This pressure (Cas) is present at the inlet to the flow-conteol valve, registers the load pressure p2 which varies between 0 {nd Pina, depend Ing upen the load. This pressure is [resent after (downstream) the pressure-reliet Valve and in the left-hand cylinder ‘chamber. The piston seals are subjectad on one ‘side to this pres- sure (friction), Pressure gauge 3: at the outlet from the cylinder the pressure is 0. Pressure gauge 2: The advantage of this circuit ies in ‘The disadvantage of this circuit lies in the fact that the cylinders only sub- the fact that the load is not “locked” Jacted to pressure from one end, and in position. That means that in the this pressure corresponds to the case of negative (auling) loads, or ‘actual load applied. The relatively low whan the loading suddenly collapses, level of friction at the piston seal the piston shoots forward and uncon usrantess a long service life and uni- trolled jericlike shifts are the result. To form shift even at low speeds. the remedy this fac, its possible to extremely iow compression volume is incorporate the special counter also advantageous in this respect. In balance circuit as shown in 5.2.3 the circuit shown, the large piston area is decisive for the lavel of the al flaw and this is of particular advantage at low traverse speeds LdBosch hydraulics, basic circuit diagrams/applications 219 52.2 Advantages and disadvantages of the meter-out circuit The diagram on the right shows the flow-control valve located in the Secondary line (meter-out elrcult) directly alter (downstroam) the load, ‘The following pressures are measured at 8 different points: Pressure gauge 1: as in 5.21, the PLESSUTE Bag IS determined by the pressure-reliat valve. This pres- ‘sure is present in the laftshand eylin= der chamber inde- pendent of the load, even when this is F = 0. The piston seal on this side is always sub- pct to maximum ‘rietion. Prossure gauge : realstors a pres: sure p2 which re- sults from the dit- ference between Pros and the load Pressure, This di ‘erence is intens|- fied according to the piston-area ralfo gin extreme cases, when the load F = 0, p2= Pax This pres Sure p2 Is present in the right-hand cylinder chamber and also loads the piston seal from this sido. The pr sure p2 decreases along with inereas- ing load and, in extreme eases, can drop to 0. Pressure gauge 3: The outlet pros- sure p3 Is always 0 po ea 8 % AL ‘Area ratio BAP AD 2 8 ho. me The advantage of this circuit lies in the fact that the load is counter- balanced. Even with negative (pulling) load, uncontrolled jerk-ine shifts do not occur as in 5.21. 2,2 Faire. ..0 ‘The disadvantage of this cirout lies in ‘the fact that the left-hand side of the Cylinder is always subject to maxi- ‘mum pressure, even when the load is ‘ata minimum. Furthermare, the rights hand eylinder chamber is subject toa ‘counterpressure which is intensified ‘according to the piston-area ratio The higher level of friction, togethar with a considerably larger compres: sion volume than in 5:21, results ina less uniform shitt characteristic (ack slip effect). Due to the pressure inten sification, variations in load have far more effect on the flow-control valve than is the case in 5.21, {the flow-contral vaive is located in the outlet from the girectional-control valve, the compression volume is Increased evon more. in addition, leakage in the dieectional-control valve affects the accuracy? 220 Bosch hydraulics, basic circuit diagrams/appli ications 5.25 Meter-in eircult with ‘counter-balance In order to take advantage of the positive results af fiting a flow-con- {rol valve in the primary ine (meterin circuit), while at the same time avoid- Ing the inherent disadvantage of such a circuit ie, the uncontrolled stick-lip effect with negative (pulling) loads, 2 pressure-relief valve Is ited to act as a counter-balance. ‘The inlot pressure is then always po: tive, even under negative (puling) The disadvantage ofthis circuit must also be mentioned, That fa, the fact, that additional power loss is incurred Which is the product of the counter balance pressure p2 and the volu- metric flow @. load conditions and when the com- pression volume is released, 6 {In ordor to minimise the power losses, a Yariable counter-balance is used Which reduces along with increasing load. Here, a special pressure-raliet valve is required (over-center valve) land an adcitional control port. This is Ps inet connected to the cylinder inet. Ifthe inlet is subject to pressure, the Ccounter-balanca pressure is reduced 40 0. iF the load collapses, the coun- tercbalance pressure is built-up again immediately Inlet prossure py | Counteralance —_/ pressure p, / | | fan | F AW | ated \ Load pressure py =p; - ps |Bosch hydraulics, basic circuit diagrams/applications 53 Graetz rectifier arrangement of check valves for flow-control valves ‘Ao has already beon mentioned, 2-nay flow-control valves are only suitable for flow in one direction. In forder to control the forward and Feverse movement of a load to an identical degree withthe aid of a single flow-control vaive, a rectifier circuit using check valves can be Used. For reasons of expedience, ihe check vaives are incorporated in an intermediate piate. 5.4 Control of different speeds In order to bo able to operate with @ umber of selectable (repeatable) ‘speeds, a number of flow-control Valves are used each of which has been set individually. These flow Control valves are switched in or out as required by means of directional ‘control valves. n the following para ‘graphs, a variety of circuit solutions are presented for different shift sequences, Fic Ee | 1 ox | | = | = | A | | | eg a 1 slow traverse For rapid traverse, the flow-contral valve is by-passed by a diractional- Control vaive and the speed is deter- mined by the availabla delivery flow from the pump, When the by-pass valve is closed, the ol low is forced through the flow-control valve with the result that the slow working traverse is effected. A 2/2 directional- control valve is needed for switch ‘over. When using the more common, 4/2 directional-control valves, the loadabilty of the T-port is to be observed (do not close it) Normally. the change-over from one Speed to the other is dependent upon the distance travelled. With mechani Gal triggering, the directional-control valve is actuated by a cam. in the cease of electro-hydraulic actuation, @ limit switch is triggered at the change: ‘ver point and transmits the electrical signal to a solenoid-onorated directio- nal-control valve by means of a velay, an electrical contactor or electronic elements, With the example shown below, the solenoid of the by-pass directional-control valve must be ‘energised in the rapid-traverse mode (satety feature).ea “ed a net we j Nesey tae tees _ = es 222 Bosch hydraulics, basic circuit diagrams/applications 5.4.2 Applications with a number of slow (working) traverses Depending upon the number of di ferant speeds required, several flow: control valves can be arranged in parallel and switched-in by means of directional-control valves. With this Circuit, itis possible to allow the oil to flow through a number of flow-contral valves at the same time with the result that the volumetric flows are ‘added. By appropriately combining the partial tlows n, thera result Z-2-1 partial-flow steps. If the setting values of the individual flow-contiol valves are double that of the preceeding valve (a2 ~ 2x01 ec), this rasuts in unitarm flow steps (refer to the diagram below right), 2Bosch hydraulics, basic circuit diagrams/applica' The following circuits show further Possibilities of realising a rapid tra~ ‘verse together with 2 working speeds. M/must be taken into account that the partial flows through two flow-control valves that are in parallel with each other are additive. In the case of two flow-control valves in series with each other. the lower of the two flows is predominant, It two thratties were to be connected in series with each other. their hydraulic resistances would be added together and a reduced total flow would result (analogy: ohmic resis- tances) 223 W~a v,~Q, +0, pe Se Sl | Laer val 1 WO aT v~Q; (@.<0) A | sat fH]o. Fa, me tT -mm@ra mmm es PBos ~ tess 224 Bosch hydraulics, basic circuit diagrams/applications 55 Start lunge 'f, upon leaving the standstill position, the eylinderis to immediately assume a given speed as set by a flow-contro| valve, the so-called start lunge often has unwanted effects. These become apparent in the form of excessive ‘starting speeds which only settle to the desired operating speed after ‘about 20 ms. Depending upon the cylinder dimensions, the pump volu- metric flow and the pressure, this means that an uncontrolled shift of ssoveral mm has taken place, ‘The reason for the start lunge is the fact that the pressure compensator in the flow-control valve is opened in its ‘start position due to the action ofits ‘pring. When a directional-controt valve is suddenly opened, the pres: sure compensator needs a certain period of time botore the control funetion is completed and it can take up the position which corresponds to ‘he load prossur. Furthermore, mention should be made ‘of the fact that the sudden release of 8 compression volume can lead to an Increase of the start lunge, ‘There are a number of measures which can be takan to avoid the start lunge. These will be dealt with indivi dually in the following ie ~ Antitunge device (stroke limiter) With the aid of this design feature, the pressure compensator can be located near to its expected final position, with the result that the tima taken for completion of the ‘control function ig reduced. The limitation thus placed on the control ange isa disadvantage ofthis, method though, Larger variations in oad (load increase) can no longer be conectea. Antitunge device (stroke limiter)Bosch hydraulics, basic circuit diagrams/applications Stand-by flow through the pressure- ‘control valve during cylinder standstil In the ciroults shown below, oll ean flow through the flow-control valve even when the cylinder is at stand stil This means that the flow-contral valve is held in @ “ready” position, The loakages in the directional-con- trol valves are to be taken into account though, because these can adversely affect the accuracy, In application b) the flow-control valve is located in the by-pass and the accuracy of the traverse speed depends here also upon the cons- taney of the pump delivery flow. ‘The power losses which are involved when the cylinder is halted ‘must also be taken into account In application ©) stand-by flow takes place through the eylindor while at ‘he same time the compression volume is pre-compressed. These measures result in best possible starting behaviour 5.8 Flow-control valves in by-pass circuits In order to improve the power etticien cy when constant-capacity pumps ‘are used tor drive purposes, flow-con- trot valves are fited in the by-pass line (refer to Page 225). The difference between the pump delivery low and the flow being ») el 1 1 : T T . AUKE, ; rl ¢ ws ub directed to the tank through the tlow- control valve is decisive here for the cylinder speed. Variations in the pump delivery, and leakages in the direo- tional-control valves, have a negative effect on the traverse accuracy. When these circuits are used, each load ‘must be driven by its own pump, | pis Li "bee ae en & A226 Bosch hydraulics, basic circuit diagrams/applications 6, Power losses in flow-control elreuits The control of the speeds of cylinders and hydraulic motors by throttling the 7 volumetric flow Q inevitably results in pawer losses, In the folowing, the magnitude of these losses is dis ‘cussed, and how they can be reduced tea minimum 6.1 2-way flow-control valve and cconstant-capacity pump + thas been presumed in the example shown, that the pump delivers excess flow whieh must be directed-off through the pressure-reliet valve. Being as this valve’s setting p, Is always above the working pressure ps determined by the load. excess pres- sure Is generated. This means that ‘excess power is also present which must be dissipated, partly at the throttle and partly at tna pressure: relief valve. In other words it must be ‘converted into heat. ‘The power, the product of pressure and flow, is represented by a shaded area in the p-Q diagram. The power loss resulting from the difference between the applied power P, and the Useful power P, is obvious in the lagram, The most practical methad a, a; PP ae therefore to keep the power loss to a ‘minimum, isto ensure that the excess Volumetric flow @ (pump size) and the excess pressure p (setting value) are kept as low as possible. This, though, is not always possible due to other phases in the working cycle which must be taken into consideration, In this respect, itis of no importance whatsoever whether the valumatrie, flow is determined by a throttle or by a 2-way flow-control valve itis also Iirelevant whether the particular com- Ponent is located in the iniat or outlet, P,Q, xp,Bosch hydraulics, basic circuit diagrams/applications 227 1 Snctamersiourcontro valve and pressure dtterence present at the The much improved Power ethciency T constant-capacity pump measuring enfice of the low-control is made apparent by the p.0 dagrer, With the Sway low-contol valve, the valve. Ths i meintaned Sorcery excess flow isnot directed away tothe prosaute somponseter The reason for Sway low-contrl the tank through the pressure valves being used lass often than tho J valve, but via tho Sid. port Thi The pressure-relat valve only 2way types, lies inthe fact that | month, aaei nel eke place at tha respond wn the working preseue. fe mpocee enna ae aL maximum set pressure, but atthe increases Wo above he nce one S-vay flow-eontol val in Particular working pressure plus the parallel th cr cari ee rE 0 ee an ina ah o, a J ny 1 » O di | 1 saintsn | 0, ap [kfte: ' ° Ly a, | + aa I | p+ Ap 4 fo, ps Pe Ties ley 68 2-way flow-control valves In Using this setup, every load again by-pass cir fas 1 be driven by is own pump. itis When 8 2-way flow-control valve is ganeelabie tal econ sae located in the by-pass, the same co ditions prevail as for a 3-way flow- control valve. Hero, the excess flow is sirected-off tothe tank through the flow-control valve atthe particular working pressure p,, and not at the maximum pressure p set at the pres sure rolief valve, be made use of{64 2.way fow-contol valve and Variable-copacty ump with pressure ator The varabl-capacity pump with pres- sure regulator dows ot oly run at = max and Q—0, but can alse operate at any @ Haute Between, In Conjunction wih 2 how-eontal valve the pump adapta automaticaly to to sel volumetic low and does not generate excess flow. The pressure p, Sot at the pressure regulator must be reached though, before the control ‘unetion is terminated, The pressure jis always above the particular Working pressure p,. This means that the pump delivers against an excess Pressure and a certain power loss is: the result. This power loss can be reduced to 2 minimum by means of —— : 65 2-way flow control valve and ‘multiple pumps. The adaptation to the volumetric flow determined by the flow-control valve can also be achieved, step-by-step, by multiple pumps. Excess flow is, iracted back to tank, at zero pres sure, either through direetional-con- trol valves or sequence valves. — a, a, correspondingly low settings at the pressure regulator which, taking nto account the requirements of other phases in the working cycle, are not always possible. ‘An additional pressure-relief valve is. fitted as a safety measure, Using this system, itis again possible to connect ‘8 number of flow-contral valves in parallel, {stow corto: Pax,Bosch hydraulics, basic circuit diagrams/applications 229 | 8.6 Variable-capacity pump with principle is alo known as “ioad- ‘The delivery low accuracy which ean combined pressure and flow-control Sensing’ As canbe seen from the be achieved is axcollam because the (efer also to Page 68) -0 diagram, this results ina highly metering thot drectly “sense A pressure-compensated low-control favourable power efficiency. The pres- this flow Changes n ficiency due to valve comprises a metering throttle sure difference atthe motering pressure variations are, as arcul, ‘and a pressure compensator. throttle, when multiplied by the flow Gompensatad for complately ,, is the only power loss involved, Whereas normally the restictor of an this Is relatively low. Mention must be made ofthe fact {he pressure compensator influences however, that a pump can only supply the main flow in order to maintain the A pressure regulator is superimposed one load ata tne Prossure ditference constant at the on the flow control, and this causes, metering once, n this ease the the pump to reduce dalivary when the This means that the pump delivery automatically adapts itself to the figure specified by the metering throttle. This occurs independently of the particular working presoure. This, iq J r i J] Motering throttle Pressure compensator a / 4 ear230 Bosch hydraulics, basic circuit diagrams/applications q u 87 Speed control by means of direct For instance, variations in efficiency _In order to prevent power losses pump adjustment at cifferent pressures adversely affect when the maximum operating pres- {vith respect to power efficiency, the the overall results unless the ioad is _ sure has been reached and the best method of controlling speed is to incoraorated in a closedloop control __pressure-reliet valve responds, the directly adjust the speed of the pump circuit. adjustment system can have a pres in accordance with the delivery-low sure control superimposed upon it requirements of the load, The pump Infinitely variable electrical control is This method is known as “pressure Can be adjusted manually, hydraull> often specified. In such cases, this override" or superimposed pressure Cally or electrically and with or ‘must be matched in design to the control without servo-assistance. This method pump is used, for example, in the hydrosta- tic transmissions for vehicles, Problems arise, particulary in statio- rary applications, due to the accuracy ‘which can be achieved and due to dt ficulties with the contro. a. uh 2 @ +f] Pe fo, 6.8 Variable-capacity pumps with 4 a = horse-power limiter i This adjustment system is mentioned for the sake of completeness. With it, | the change of delivery flow takes Hl place depending upon the working | pressure and in accordance with 3 Characteristic curve for constant | power (hyperbola p - = constant). I In this manner, the rotational speed of | {he load autoriaticaly adapts tothe | force or torque required. The installad | ative powers always fully utlised, butisnover exceede. Excess, hydraulic power never occurs | In order to prevent power losses when the maximum operating pres- ‘sure has been reached and the rossure-rlict valve responds, the ‘adjustment system can have a pres ‘ure regulation superimposed upon it (pressure override" or superimposed pressure contro),Bosch hydraulics, ba: 7, Differential ciuit Inthe case of cylinders with the piston rod at only one end, the ditfe- ential circuit ean be used in order to Increase the speed. Here, pressure is applied to both piston surfaces and the piston is forced outwards due to the ditference in power arising from the difference in the areas. The oil ‘expelled from the rod end is returned to the large piston area. The effective area now corresponds to the area of the piston rod, The result is an Increase in speed with less appliod force in comparison to cylinders in which oil only enters at one end, Being as both sides of the piston are subject to pressure, Increased friction ‘must be expected. For this reason, the differential circut is only to be used up to a piston-area ratio AGAS2 Using appropriate citcuitry with suit- able directional-control valves, this principle can be applied for rapid-ira- ‘verse purposes as shown. circuit diagrams/appli i232 Bosch hydraulics, basic circuit diagrams/applications 8. Locking with pilot-operated check | Ifa cylinder is to be maintained in a aiven position even though subject to extemal forces, itis generally not z sufficient to block the working ports 6 of the spool-type directional-contro! valves. In these positions of the valve, | | i Jeakages cause the load to be slowly lowered, or the cylinder to “creep”. In ‘dar to prevent this happening, pilot- operated check valves are fitted. The J] following will demonstrate some basic Circuits using this principle. 8.1 Pilot pressure picked-up from a the opposite eylinder port r CH When the valve is blocked, the ports UP Aand Z are to be relieved of pressure, That is, the directional-control valve ‘symbol as shown is to be used, y During the lowering process, the pilot pressure is taken from the upper cylinder port. Due to the outlet being Diocked at first, this pressure builds up. At the instant in which the check valve opens, the pressure colianses } and the load is lowered, with the WX | a CATHIE result that the check valve closes a ‘again, This leads to “stick-sip" lower- ing movements. In order to prevent this, the lowering speed is controlled by a tlow-control valve. & further pos- sibility isto use a pressure-ralot valve ‘0 suppor the load, See Ths pec bata aen wich ny —©§ Se available on the market are a combi Ration of these valve functions must be taken Into account that pressure in the upper cylinder line is added to tho actual load pressure ‘and, a8 a resul, increases the pilot pressure needed to open the check 4 ‘valve. In the case of a cylinder with a Bilton rod extending from both ends, ? the pilot pressure is calculated as Z follows: For pressure balance at the check valve applies: pathy cs Aa Closing force = Opening force PuxAy Bee iaroae 6 The equation is resolved for P, Pak Ae Pe A Pus Ar=— PLA Pear Ay "== Pa, x =a) PL = Load pressure Pa = Pilot pressure Ay = Area of valve poppet ‘Az = Area of pilot pistonBosch hydraulics, basic circuit diagrams/applications 233 ‘The use of a pilot-operated check valve with a pilot ratio Ay: Ay— 1 2 ¢ ‘means that the plot pressure required to open the valve Pas Pog aa is Identical to the load pressure ‘When using a pilot-operated check valve with a pilot ratio Ay: Ay= 1:5 Pam Pig iano eer fesovlinger concerned Nas unequal Ion the othr hand, th load hangs Taking @=2,and using check ave. “] platon areas and thelcadissupported from the cylinder pision the plot vitharailo As eteattensene | by the cylinder piston (as opposed to pressure which is effoctive from in anintinte pict pressure, Le. the hanging from iO, the plot pressure above is stepped-up in accordance valve never open. In such conse ot. whichis effective from above is with @, Le. the required pilot pressure only to ensure thatthe valve apen, @ stepped-down in accordance with thes, pilot-controlled valve must be used piston-area ratio With @ ratio A, : Az approx.1: 5, 4 od The required pilot pressure i there- fore: eta ee RI 1+ OX Pg Ee rtexp, AeSe ee a A A 284 Bosch hydraulics, basic circuit diagrams/applications 82 External pilot pressure If the pilot pressure isto be supplied from an external pressure source, the pressure is calculated in accordance ‘with the formula At Pr= Pe: gt In other words, this pressure depends upon the load pressure which is effec- tive at connection B and upon the relationship between the surface area of the valve seat and the pilot piston, Here, the pilot-operated check vaive ‘can be regarded as the main slage of 2 pilot-operated directional-control valve. Lowering takes place due to the weight of the load. The eylinder has ‘oniy one connection 83 Pllot-pressure pickup from load As shown hers, the pilot pressure ean be picked up from the eylinder line to which the load pressure is applied. This is under all circumstances sufficient to open the check val order to prevent “stickslio" or jerky movements during lowering, the lowering speed is to be.contrelled by a throttle ora flow-control valve. A Seat-type valve is also to be used here as the pilot vaive in order to prevent leakages occuring Very often, the complete valve comb nation is incorporated in a single housing (lowering brake valve, load: contra! block) 184 Shock absorber in the cylinder lines ‘The most practical method of pre- venting pressure peaks occuring in the cylinder line due to sudden, or ‘excessive, braking ar blows on the cylinder, 16 to install a pressure-reliet valve in the shunt connection, This must be a seat-type valve which ‘exhibits no leaks at all ni