1.

Hydraulic Pump Calculations

–Hydraulic Piston Pump.jpg

Horsepower Required to Drive Pump:

GPM x PSI x .0007 (this is a ‘rule-of-thumb’ calculation)

Example: How many horsepower are needed to drive a 5 gpm pump at 1500 psi?

GPM = 5 PSI = 1500

GPM x PSI x .0007 = 5 x 1500 x .0007 = 5.25 horsepower

–Hydraulic Pump.jpg

Pump Displacement Needed for GPM of Output Flow:

231 x GPM ÷ RPM

Example: What displacement is needed to produce 5 gpm at 1500 rpm?

GPM = 5

RPM = 1500

231 x GPM ÷ RPM = 231 x 5 ÷ 1500 = 0.77 cubic inches per revolution

Pump Output Flow (in Gallons Per Minute):

RPM x Pump Displacement ÷ 231

Example: How much oil will be produced by a 2.5 cubic inch pump operating at 1200 rpm?

RPM = 1200
Pump Displacement = 2.5 cubic inches

RPM x Pump Displacement ÷ 231 = 1200 x 2.5 ÷ 231 = 12.99 gpm

2. Hydraulic Cylinder Calculations

–Double Acting Hydraulic Cylinder.jpg

Cylinder Rod End Area (in square inches):

Blind End Area – Rod Area

Example: What is the rod end area of a 6″ diameter cylinder which has a 3″ diameter rod?

Cylinder Blind End Area = 28.26 square inches

Rod Diameter = 3″

Radius is 1/2 of rod diameter = 1.5″

Radius2 = 1.5″ x 1.5″ = 2.25″

π x Radius2 = 3.14 x 2.25 = 7.07 square inches

Blind End Area – Rod Area = 28.26 – 7.07 = 21.19 square inches

Cylinder Blind End Area (in square inches):

PI x (Cylinder Radius)2

Example: What is the area of a 6″ diameter cylinder?

Diameter = 6″

Radius is 1/2 of diameter = 3″

Radius2 = 3″ x 3″ = 9″

π x (Cylinder Radius)2 = 3.14 x (3)2 = 3.14 x 9 = 28.26 square inches

Cylinder Blind End Output (GPM):

Blind End Area ÷ Rod End Area x GPM In

Example: How many GPM come out the blind end of a 6″ diameter cylinder with a 3″ diameter rod
when there is 15 gallons per minute put in the rod end?

Cylinder Blind End Area =28.26 square inches

Cylinder Rod End Area = 21.19 square inches

GPM Input = 15 gpm

Blind End Area ÷ Rod End Area x GPM In = 28.26 ÷ 21.19 x 15 = 20 gpm
Cylinder Output Force (in pounds):

Pressure (in PSI) x Cylinder Area

Example: What is the push force of a 6″ diameter cylinder operating at 2,500 PSI?

Cylinder Blind End Area = 28.26 square inches

Pressure = 2,500 psi

Pressure x Cylinder Area = 2,500 X 28.26 = 70,650 pounds

What is the pull force of a 6″ diameter cylinder with a 3″ diameter rod operating at 2,500 PSI?

Cylinder Rod End Area = 21.19 square inches

Pressure = 2,500 psi

Pressure x Cylinder Area = 2,500 x 21.19 = 52,975 pounds

–Hydraulic Cylinder.jpg

Cylinder Speed (in inches per second):

(231 x GPM) ÷ (60 x Net Cylinder Area)

Example: How fast will a 6″ diameter cylinder with a 3″ diameter rod extend with 15 gpm input?

GPM = 6

Net Cylinder Area = 28.26 square inches

(231 x GPM) ÷ (60 x Net Cylinder Area) = (231 x 15) ÷ (60 x 28.26) = 2.04 inches per second

How fast will it retract?

Net Cylinder Area = 21.19 square inches

(231 x GPM) ÷ (60 x Net Cylinder Area) = (231 x 15) ÷ (60 x 21.19) = 2.73 inches per second

GPM of Flow Needed for Cylinder Speed:

Cylinder Area x Stroke Length in Inches ÷ 231 x 60 ÷ Time in seconds for one stroke

Example: How many GPM are needed to extend a 6″ diameter cylinder 8 inches in 10 seconds?

Cylinder Area = 28.26 square inches

Stroke Length = 8 inches

Time for 1 stroke = 10 seconds

Area x Length ÷ 231 x 60 ÷ Time = 28.26 x 8 ÷ 231 x 60 ÷ 10 = 5.88 gpm

If the cylinder has a 3″ diameter rod, how many gpm is needed to retract 8 inches in 10 seconds?

Cylinder Area = 21.19 square inches

Stroke Length = 8 inches

Time for 1 stroke = 10 seconds

Area x Length ÷ 231 x 60 ÷ Time = 21.19 x 8 ÷ 231 x 60 ÷ 10 = 4.40 gpm

Fluid Pressure in PSI Required to Lift Load (in PSI):

Pounds of Force Needed ÷ Cylinder Area

Example: What pressure is needed to develop 50,000 pounds of push force from a 6″ diameter
cylinder?

Pounds of Force = 50,000 pounds

Cylinder Blind End Area = 28.26 square inches

Pounds of Force Needed ÷ Cylinder Area = 50,000 ÷ 28.26 = 1,769.29 PSI

What pressure is needed to develop 50,000 pounds of pull force from a 6″ diameter cylinder which
has a 3″ diameter rod?

Pounds of Force = 50,000 pounds

Cylinder Rod End Area = 21.19 square inches

Pounds of Force Needed ÷ Cylinder Area = 50,000 ÷ 21.19 = 2,359.60 PSI

3. Hydraulic Motor Calculations

–Hydraulic motor.jpg
GPM of Flow Needed for Fluid Motor Speed:

Motor Displacement x Motor RPM ÷ 231

Example: How many GPM are needed to drive a 3.75 cubic inch motor at 1500 rpm?

Motor Displacement = 3.75 cubic inches per revolution

Motor RPM = 1500

Motor Displacement x Motor RPM ÷ 231 = 3.75 x 1500 ÷ 231 = 24.35 gpm

Fluid Motor Speed from GPM Input:

231 x GPM ÷ Fluid Motor Displacement

Example: How fast will a 0.75 cubic inch motor turn with 6 gpm input?

GPM = 6

Motor Displacement = 0.75 cubic inches per revolution

231 x GPM ÷ Fluid Motor Displacement = 231 x 6 ÷ 0.75 = 1,848 rpm

Fluid Motor Torque from Pressure and Displacement:

PSI x Motor Displacement ÷ (2 x π)

Example: How much torque does a 2.5 cubic inch motor develop at 2,000 psi?

Pressure = 2,000 psi

Motor Displacement = 2.5 cubic inches per revolution

PSI x Motor Displacement ÷ (2 x π) = 2,000 x 2.5 ÷ 6.28 = 796.19 inch pounds

Fluid Motor Torque from GPM, PSI and RPM:

GPM x PSI x 36.77 ÷ RPM

Example: How much torque does a motor develop at 1,200 psi, 1500 rpm, with 10 gpm input?

GPM = 10

PSI = 1,500

RPM = 1200

GPM x PSI x 36.7 ÷ RPM = 10 x 1,500 x 36.7 ÷ 1200 = 458.75 inch pounds second

Fluid Motor Torque from Horsepower and RPM:

Horsepower x 63025 ÷ RPM

Example: How much torque is developed by a motor at 12 horsepower and 1750 rpm?

Horsepower = 12

RPM = 1750

Horsepower x 63025 ÷ RPM = 12 x 63025 ÷ 1750 = 432.17 inch pound

–hydraulic-system.jpg
4.Fluid and Piping Calculations

Velocity of Fluid through Piping

0.3208 x GPM ÷ Internal Area

What is the velocity of 10 gpm going through a 1/2″ diameter schedule 40 pipe?

GPM = 10

Internal Area = .304 (see note below)

0.3208 x GPM ÷ Internal Area = .3208 x 10 ÷ .304 = 10.55 feet per second

Note: The outside diameter of pipe remains the same regardless of the thickness of the pipe. A
heavy duty pipe has a thicker wall than a standard duty pipe, so the internal diameter of the heavy
duty pipe is smaller than the internal diameter of a standard duty pipe. The wall thickness and
internal diameter of pipes can be found on readily available charts.

Hydraulic steel tubing also maintains the same outside diameter regardless of wall thickness.

Hose sizes indicate the inside diameter of the plumbing. A 1/2″ diameter hose has an internal
diameter of 0.50 inches, regardless of the hose pressure rating.

Suggested Piping Sizes:

– Pump suction lines should be sized so the fluid velocity is between 2 and 4 feet per second.

– Oil return lines should be sized so the fluid velocity is between 10 and 15 feet per second.

– Medium pressure supply lines should be sized so the fluid velocity is between 15 and 20 feet per
second.

– High pressure supply lines should be sized so the fluid velocity is below 30 feet per second.
–simple-hydraulic-system.jpg

5. General Conversions

To Convert Into Multiply By

Bar PSI 14.5
cc Cu. In. 0.06102
°C °F (°C x 1.8) + 32
Kg lbs. 2.205
KW HP 1.341
Liters Gallons 0.2642
mm Inches 0.03937
Nm lb.-ft 0.7375
Cu. In. cc 16.39
°F °C (°F – 32) ÷ 1.8
Gallons Liters 3.785
HP KW 0.7457
Inch mm 25.4
lbs. Kg 0.4535
lb.-ft. Nm 1.356
PSI Bar 0.06896
In. of HG PSI 0.4912
In. of H20 PSI 0.03613

For more Hydraulic products information,please visit our products website: /products

What is hydraulic power pack components ?

What Is a Hydraulic Power Pack?

What are the applications for hydraulic power packs?

Mobile hydraulics applications have recently been increasing so much with hydraulic power packs.
Some applications are as follows; dump trailers, electric sanitation trucks, snowplows, telescopic
logistics equipment, like the dock leveler, car tailgates, wing trucks, electric pushcarts, and electric
pallet lifts. Other uses include car lifts, scissor lifts, electric operating tables, and special equipment
on elevators. Compact hydraulic power units (HPU) work well at high pressure, with its low flow
hydraulic system, small size, simple elements, and affordable price.

How many different types of hydraulic power units are there?

These units include; single-acting hydraulic power units, double-acting hydraulic power units, power
units, and other complex special effects work.

In the motor voltage are DC hydraulic power units, and AC hydraulic power units. In the tank
installation are vertical or horizontally mounted hydraulic power units.

The valves are controlled by manual operation hydraulic power units, and electric control hydraulic
power units.

Here is a DC Hydraulic Power Unit drawing to show you what the main Hydraulic power packs
components are:
1-DC motor cover 2-DC motor 3-Shaft joint 4-Relief Valve 5-Flow control valve 6-Central Manifold 7-Hydraulic Gear
Pump 8-Return oil pipe 9-Suction pipe 10-Hydraulic oil tank
11-Air breather 12-suction filter 13-two position two way normally closed solenoid valve 14-Check Valve 15-
Mounting Bracket 16-Remote control pendant
If you want know how to wire DC Hydraulic Power Pack,you can check our hydraulic power pack
wiring diagram .

What components do hydraulic power units components include?

(HPU) Hydraulic power units are a hydraulic system with hydraulic actuators (hydraulic cylinders,
hydraulic motors) connected to the control valve operation to achieve the operation of the equipment
for the adopted oil pressure apparatus. Hydraulic power units come complete with a power section
(electric motor, hydraulic pump), the control section (pressure valves, directional control valves, flow
control valves), and the auxiliary section (couplings, manifold block, suction pipe, return pipe, tank,
air breather, etc.).
First, the Power Section

1) Motor – hydraulic power unit power source

The motor hydraulic power unit’s main role is to convert electrical energy into mechanical energy.
Generating a driving torque, hydraulic power units function as a power source. Hydraulic power units
are commonly classified according to the power supply of the motor, and can be divided into DC
motors and AC motors. Where in the AC motor and the DC motor include 2 poles and 4 poles.
Electric motor common parameters

1. Rated power is the motor’s maximum working power recommended operating conditions.
POWER RATING is motor power.
2. Rated voltage or operating voltage. Since the motor can generally operate at different
voltages, the voltage is directly related to the speed, and other parameters have to change
accordingly, so that the voltage is only a suggestion.
3. No-load speed. The unit is RPM, meaning revolutions per minute. Since there is no load
speed reverse torque, the output power and the stall situation is different, the effect
parameters only provide maximum speed of the motor at a predetermined voltage.
4. Stall torque is an important parameter to take a lot of the load of the motor. That is, when the
motor is reversed by an external force to stop the rotation torque. If the motor stall
phenomenon occurs often, it will damage the motor, or burned driver chips, so when you
choose the motor, which, in addition to speed, is the first parameter to be considered.
Usually the relationship values and the operating voltage is not very close. Note that,
however, stalled over time, the motor temperature rises rapidly, the motor’s value will decline
rapidly.
5. No-load current is closely related to current and torque. There is certainly no-load current,
because voltage and energy formed is divided into potential energy and heat energy
consumption. Heat is related to the motor coil, the better the motor, at no load, the smaller
the value.
6. Starting current. This parameter is also important. For a good motor, under the same
acceleration, the starting current will be small.

2) Hydraulic pump – the heart of the hydraulic power unit

Hydraulic pump means a hydraulic power unit capable of converting mechanical energy into
hydraulic pressure. Driven by the motor, providing flow and pressure of the hydraulic actuator action
desired. Thus, it can be said that the hydraulic pump is the “heart.” There are several types of
hydraulic pumps: gear pumps, vane pumps, and piston pumps.

Gear pumps

Compact hydraulic power units normally work with hydraulic gear pumps. At present, the industry’s
leading manufacturer in Italy is Marzocchi pumps High Pressure Gear Pump Company. Gear pump
advantages are: simple structure, easy fabrication, low cost, small size, light weight, self-priming
performance, not sensitive to pollution of the oil, reliable, and high speed range.

How Hydraulic gear pump work

As shown capstan clockwise, then seal the suction chamber at T, because the tooth is disengaged
children volume increases, the formation of a vacuum, atmospheric pressure hydraulic oil tank into
the suction chamber T, the room filled with alveolar, this is the pump suction process; with the
rotation of the gear, with oil constantly being brought into pressure oil chamber P, teeth into
engagement on that side, the volume decreases, forcing oil output, this is the process of pumping
oil. And syringe injection medicine procedure is very similar.Gear pumps common parameters

 Pressure rating refers to the maximum under the premise volumetric efficiency of the pump,
and the life of the rated speed, continuous operation of the pump allows the use of pressure
to ensure that more than this value is overloaded. Rated pressure and maximum working
pressure of the pump pressure is not actually at work.
 Displacement refers to the pump shaft rotation, excluded volume of oil. Here we must
distinguish between displacement and rated flow. Rated flow at rated pressure and speed
conditions, the output of a predetermined flow rate. Speed-dependent, but no relationship
between displacement and speed.
 Efficiency, broken down into mechanical efficiency and volumetric efficiency, showed losses
in torque and pump flow.

Second, the control section As with the development of the hydraulic power unit cartridge valve in
the increased range, a wide range of hydraulic power units are also increasing. The main production
base for the current international cartridge valves in the United States include Hydraforce Hydraulics
Cartridge Valves, Sun Hydraulics, Eaton vickers (Eaton), Parker Hannifin (Parker), and Fluid
Control. Sterling Hydraulics and Integrated Hydraulics are companies in the UK. In Germany there
are Bosch-Rexroth, HYDAC, and Fluid TeamWandfluh, and Bucher-Frutigen are from Switzerland.
In Italy there are Comatrol and Oil-Control. In Sweden, and Denmark Sauer-Danfoss. Keta
Hydraulics and Haihong Hydraulics are from China. And Target Hydraulics company from Ningbo
Hydraulics.
1) Pressure control valves Pressure control valves on the hydraulic power units with pressure relief
valve, sequence valve, relief valve, are pressure relay-based. Almost each hydraulic power unit
comes complete with a relief valve. Sequence valves, relief valves, and pressure switches on some
special hydraulic power units have a sequence of actions, and the same system has different
working pressures used, such as dock leveler hydraulic power units for logistics equipment and
paper cutter production line hydraulic power units.Relief Valve – umbrella of hydraulic power
unit Pressure relief valves on the hydraulic power unit have primarily a security role, they limit the
maximum pressure to avoid other hydraulic components, and pipe damage. As part of a back
pressure relief valve in the hydraulic power unit, causing back pressure to increase the stability of
motion.

1—Valve body 2—valve spool 3—valve body 4—spring seat 5—spring 6—adjusting lever 7—
screw-in body 8—Locking nut

How a relief valve works Under normal operation ①chamber to chamber ② closed until the liquid
pressure chamber ① sufficient to overcome the spring force of the valve body from the valve seat,
①chamber communicating with the chamber②, the flow of oil from the chamber ①cavity②.
2) Directional control valve Hydraulic power units have varied different types of directional control
valve, check valves, P-O-check valves, shuttle valves, solenoid valves, hydraulic control valves,
electric proportional valve, and so on.

 Check valve (one-way valve) oil traffic in one-way.

One-way valves, also known as check valves, allow fluid only in one direction through the reversing
valve closing direction. The main role of the check valve in the hydraulic power unit is: to keep the
system pressure constant for a period of time and other pressure retaining components, installation
preventing normal operation of the hydraulic pump, and hydraulic shocks in pump outlet position, the
check valve installed in the back part oil used as a back-pressure valve. According to the role of one-
way valve in the hydraulic power unit, its performance was mainly: oil pressure loss circulation of
small forward, reverse seal better performance, quick action, low noise.
1-Valve seat 2-Check valve spool 3-Spring 4-Screw Plug

How check valves work The pressure port① is higher than the pressure port② plus spring force,
the spool is pushed, the channel is open, fluid forward through the check valve (① flow to ②).When
the port ② pressure plus the spring force is higher than the port ① pressure spool is pressed
against the spring force and fluid pressure on the valve seat, the flow is turned off.

 Directional valve – oil traffic red and green lights

Directional valve is the largest amount components of hydraulic power unit request. Directional
valve use of different relative positions in hydraulic power pack. Hydraulic power unit requirements:
the oil through a less pressure loss, less amounts of the oil leakage gap between the mouth
commutation reliable, sensitive, reversing smoothly without impact. According manipulation way
valve used in the hydraulic power unit valve can be divided into: manual valve, solenoid valve, and
motorized valves For example, in the automotive lift hydraulic power unit, electric pallet truck
hydraulic power unit, electric car pushing hydraulic power unit, hydraulic power units, and other
tipper trailers on two two-way solenoid valve with the most.

Hydraforce SV type two-way solenoid valve works When the solenoid valve coil power, the two-way
solenoid valve can do a one-way valve to allow flow from ① to ② chamber cavity, and the cavity
reverse blocking oil from ② to ①.Solenoid valve coil is energized, the lifting force generated by the
coil, valve open, fluid chamber from ② to ①, ② and ① chamber to the fluid chamber due to
structural reasons strong resistance.
3) Flow control valve Flow control valve referred to the flow valve, is by changing the orifice flow
area to achieve flow control. It is a control valve components to control the speed of movement of
the element. Flow valve can be opened as a small mark of “taps.”Flow valves can generally be
divided into: a throttle valve, 2-way flow control valve (also known as pressure-compensated flow
valve), the three-way flow control valve. Currently on the hydraulic power units, Hydraforce is mainly
used for NV Throttle and Comatrol’s SC13 type 2-way flow valve.

Hydraforce FR-type pressure compensated flow control valve works FR-type pressure compensated
flow control valve ② from holding chamber effluent flow rate constant and is not affected by the load
pressure changes in the circuit downstream of the chamber ②, when the flow through the valve in
the control orifice pressure differential created more than 5.5bar, valve begins response to load
changes within a pressure range of 7.6 ~ 240bar can maintain accurate flow, reverse flow (chamber
②to chamber①) through the control orifice, no pressure compensation, and orifice same. Third,
the auxiliary section Hydraulic auxiliary components of the hydraulic power unit have a “supporting
role”, but it is also an important part of the hydraulic power unit, Types of hydraulic auxiliary element
is varied, including: tank, filter, suction pipe, return pipe, an intermediate manifold, control switches,
pressure gauge, accumulator, and so on. The right choice and ensure the rational use of the
hydraulic power unit is reliable, stable and has a very important auxiliary hydraulic components.

 Tank (Hydraulic Reservoir)- the hydraulic medium required for storage of the hydraulic
system, as a heat sink, the role of the liquid medium in air separation and precipitation of
impurities.
 Filter – filtration of impurities mixed in with the oil, foreign particles in a controlled hydraulic
power unit normal operating range, the protection of hydraulic components.
 Central manifold – Installation Connecting the motor and gear pump, simplifying the piping,
integrated control valve of the hydraulic power unit compact and convenient. Replace with a
different intermediate manifold control valve can be achieved on different principles of
hydraulic power unit, which makes the intermediate manifold high versatility.

Product Content
Cartridge solenoid valves A cartridge directional solenoid valve will control which element the
hydraulic fluid will flow to. There are many different types of directional control valves. Normally,
valves are designed with coil and cartridge spools or poppets.The valve is generally specified
by a number of positions and a number of ways (ports). The valve is made up of two parts, the
body and the spool.
 Two (2) Position, Two (2) way This valve has two positions (2 boxes) and 2
ways (ports); thus 2 position, 2 way. This valve is normally closed because both ports are blocked
when in neutral.

Three (3) Position, Four (4) way This valve has three positions (3 boxes)
and 4 ways (ports); thus 3 position, 4 way. It is shown with a closed center, when the valve is neutral
all ports are blocked. The small boxes on each end with diagonal lines through them, C1 and C2, are
electrical coils, this is an electrically actuated valve. The port marked P is Pressure and the port
marked T drains to tank. The ports marked A and B connect to an external device, like a cylinder.
When C1 is energized the valve will shift, putting pressure to the B port and draining the A port to the
tank. Likewise when C2 is energized the pressure port connects to the A port and the B port drains
to the tank.
Typical applications: hydraulic power packs, hydraulic cartridge valve manifold systems, mobile
hydraulics, and etc.

Hydraulic flow valves

Cartridge flow control valves manage the flow by decreasing or increasing the opening at the
throttling point. They are called throttle valves. The throttle check valve for speed control in one
direction of flow.
This unit is a screw-in, cartridge type, bi-directional hydraulic flow valve. Normally we use it in T line
of our hydraulic power unit to control cylinder speed.

Typical applications: hydraulic power units, hydraulic cartridge valve manifold systems, mobile
hydraulics, and etc.

Hydraulic pressure valves

 Hydraulic pressure valves include hydraulic pressure reducing
valves and hydraulic relief valves. Hydraulic Relief Valve.All hydraulic systems must have a
pressure relief valve in P line with the pump. The pressure relief will drain into the tank. Because
hydraulic fluid oil is normally non compressible, if the fluid can’t go anywhere, the pump will stop or
fail. And this may damage the pump and system components. The relief valve will control the
maximum pressure in the hydraulic system to limit the system pressure below the safety pressure
level.

Typical applications: hydraulic power packs, hydraulic cartridge valves, manifold systems, mobile
hydraulics, etc.