Volume5 Study of Hydraulic Circuits

Q. S.
Khan
B. E. (Mech.)
Tanveer Publications,
Mumbai - 78
CONTENTS
Hydraulic Circuit 10.1to 10.62
10.1 What is circuit?

circuit?
10.2 Classification of hydraulic circuit.
10.3 Selection of different
different circuit for some function.
10.4 Selection of working pressure.
10.5 Pressure
Pre ssure in hydraulic
hydraulic Ststem.
10.6 Calculation
Calculation of heat generation in hydrauli
hydraulicc Ststem.
Sts tem.
10.7 Sequence
S equence and cycle diagram.
diagram.
10.8 Circuit diagram ffor or modular type power pack.
10.9 Use of filter
filter in hydraulic circuit.
10.10 What is pumpin
pumping g unit and power pack unit?
10.11 Pressure control circuit.
10.12 Pressure
P ressure holding circuit.
circuit.
10.13 Decompression
Deco mpression circuit.
circuit.
10.14 Hydraulic
Hydr aulic circuit
circuit with back pressure.
10.15
10.1 5 Back Pressur
P ressuree in a hydraulic
hydraulic cylinder.
cylinder.
10.16 Hydraulic
Hydraulic circuit using sequence valve.
va lve.
10.17 Direction contro
controll circuit.
circuit.
10.18 Regeneration
Regenerat ion circuit.
circuit.
10.19 Brake circuit.
circuit.
10.20 Flow control
contro l circuit.
circuit.
10.21 Synchronisation
Synchronisation circuit.
10.22 Circuit diagram of drill.
Study of Hydraulic Circuit What is circuit
10. Introduction to Hydraulic Circuit

10.1. What is Circuit?
• The Hydraulic power is generated by pumps, and supplied to hydraulic
hydraulic actuators.
actuat ors. This hydraulic
hydraulic
power must
must be controll
controlled inin order to achi
achieve
eve the desired
desired functi
function.
on. A hydraul
hydraulicic circui
circuitt is basical
basically
ly
designed to have effective
effective control
con trol over
o ver this generated
generat ed power.
po wer. A hydraulic
hydraulic circuit consists of fluid
conductor such as steel pipe, hoses, and manifold
manifold block to transfer fluid.
fluid. It has valves to co control
ntrol
pressure, direction,
direction, and
and flow
flow of hydrauli
hydraulicc fluid.
fluid. And hydrauli
hydraulicc accessories
accessories for better control of
various parameter
para meter and to have safety and long life of hydraulic
hydraulic system.
In this chapter we will study various types of hydraulic circuit.
Generally three types of controls
contr ols we do over generat
generated
ed hydraulic
hydraulic power.
powe r.
a) Direction control.
b) Pressure
Pressure control.
control.
c) Flow control
• Direction control
contro l feature, and direction control
contr ol valve is common
common in almost all the hydraulic
circuits.
• Pressure
Pressu re control
cont rol feature and safety
sa fety valve
valve is also
also comm
co mmonon in all the hydraulic system. In addition
to main system pressure, some
so me circuits
circuits are specially
specially designed
designed to reduce pressure,
pressure , to generate
ge nerate back
pressure,
pressure, to have
have diff
differen
erentt press
pressure
ure at diff
differen
erentt parts
parts of the circui
circuit.
t.
• Some circuits are
ar e exclusively
exclusively designed to control
contro l flow
flow of
o f hydraulic
hydraulic fluid in
in the system.
• A complex hydraulic
hydraulic circuit may have
have all the three features in it. That is control
contro l of direction of
fluid,
fluid, and control
co ntrol of
o f its pressure and flow.
flow.
• To thoroughly
thoro ughly understand
understa nd hydraulic circuit
circuit and simplif
simplify
y its study, we will
will classify
classify various
various types
of hydraulic
hydraulic circuit in to various categories,
categ ories, then
t hen study each category
categ ory in detail.
“Design and Manufacturing of Hydrauli

Hydrauli c Presses.”
Presses.” ©: Q.S. Khan
Khan 10-1
Study of Hydraulic Circuit Classification of Hydraulic Circuit
10.2 Classification of Hydraulic Circuit
Hydraulic power system or hydraulic circuit

circuit could
co uld be divided
divided in to two broad
bro ad categories.
categ ories.
a) Closed-loop circuits:-
A close-loop
close-loop hydraulic circuit has all the basic elements
elements of hydraulic
Feed-back
circuit, such as hydraulic pump, hydraulic valves to control direction, flow Mechanism
and pressure, hydraulic accessories etc. In addition to these component it
also has a feed
f eed back mechanism which continuously
continuously monitors system output.
It generates a signal which is proportional to output, then it compares it with
input or command or reference signal. If the two matches, then there is no
adjustment and the system continue to operate as programmed. If there is a
difference between
between the input command signal and the feed back signal, then
the system has provision and mechanism to correct and adjust the output
to match with the command requirement.
CLOSE-LOOP CIRCUIT
An electro-hydraulic servo system is a feed back system which measures
measures
and corrects the output.
b) Open loop circuit:-
In this type of
of circuit, we do not
not get feed back.
An open-loop hydraulic circuit do have all the basic

elements of hydraulic circuit but it does not have feed-back
machenism.
OPEN LOOP CIRCUIT
Open loop as well as closed-loop circuit could be further
sub-divided into two categories.
1) Open circuit
2) Close circuit
M
In open circuit the fluid is sucked
sucked from reservoir by pump. Fluid passes through
hydraulic component and again exhausted to reservoir. Reservoir has excess OPEN CIRCUIT
quality of fluid then what is required
r equired by hydraulic circuit. And quantity of fluid in
Q
hydraulic circuit could be changed without any restrictions.
M
In close loop, reservoir is eliminated and suction of pump is connected to
Q
exhaust line of circuit. Hence a fixed quality of fluid keeps on circulating in
COLSE CIRCUIT
hydraulic system.
Majority of hydraulic systems are open circuit. Close circuit is used for sophisticated, highly
accurate and compact machineries.
Constant flow circuit and demand flow circuit:-
These two terms are also used for

for hydraulic circuit. T
c
In constant flow circuit, full discharge
dischar ge of pump always flows through
the system and returns to reservoir, The volume of flow does not change
in minimum
minimum as well as in maximum pressurepressu re condition.
While in demand
demand flow circuit, the volume of fluid circulating
circulat ing through
circuit changes with demand or requireme
r equirement
nt of circuit. Volume of fluid
could be reduced by using variable discharge pump or other type of
hydraulic valves.
• Most of the hydraulic systems are designed as per open loop and Demand flow circuit
variable with displacement pump
open circuit. Hence first we will study open circuit in detail.
Khan 10-2
10.3 Selection of different circuit for same function
Suppose a hydraulic cylinder of 35 ton capacity has to move a load for distance of 50 cm.
Now said
said circuit
circuit could be made in many
many ways
ways . Four of them are as follow
follow..
TYPE 2
TYPE 1
P M
P M
TYPE 3 TYPE 4
P M
• In first
first system
system actuator moves
moves with
with same speed throughout
throughout it’s
it’s stroke. And
And maxi
maximum
mum working
working
pressure
pressure is availab
available
le from start of stroke, till
till end of strokes.
• In second
second and fourth
fourth system
system,, actuator could
could have
have fast
fast approach
approach and return
return speed
speed and show
show
pressi
pressing
ng speed.
speed. And
And full
full working
working pressure
pressure will
will be availa
availabl
blee in last
last slow
slow pressin
pressing
g operation.
operation.
• In third
third system
system,, we can have high
high speed
speed as well as full
full working
working pressure
pressure throughou
throughoutt stroke. But
accumulator
accumulator takes some
so me time
time for charging.
charging. It cannot give continuous high speed and pressure
p ressure
without charging, and some delay time.
time.
All the four system has their
the ir unique advantage
advantag e and disadvantage;
d isadvantage; similarly
similarly any hydraulic
hydraulic circuit
could be designed in many ways, hence knowing different types of vlaves and components,
compo nents, their
t heir
functions their
the ir cost and knowing
kno wing basic requirement
requirement of hydraulic machine isis must
must before designing
d esigning
hydraulic system.

Khan 10-3
10.4 Selection of working

working pressure
pressure
With the help of
o f following
following example, we w wililll study the importance of
o f working pressure
pressu re while
designing a hydraulic circuit.
Examples:
• Suppose
Suppo se we want to move a weight of 35 ton at the t he speed of 160 cm/mi
cm/min.,
n., for a distance of
50cm
• We select a simplest
simplest hydraulic
hydraulic circuit for said purpose, which consists of a motor, pump, relief
valve, direction control
cont rol valve, hydraulic
hydraulic cylinder
cylinder and standard
s tandard hydraulic
hydraulic accessories.
acces sories.
5
Bill of Material
Sr.No. Name of components Functions
1 Motor Prime mover
2 Pump To deliver oil
3 Relief valve To regulate pressure
4 Direction control valve To control direction of
cylinder
5 Hydraulic cylinder Actuator
4 6 Oil tank Oil reservoir
7 Standard accesories To maintain quality of oil
1 and safety of system
3 P M
2 7 7
7
6 7
HYDRAULIC CIRCUIT DIAGRAM
• We will select three pressure 35 0 kg/cm2 and find the capacity

pr essure 70, 200 and 350 capa city of pump, valves
and standard accessories to have 160 cm/min speed while moving 35 ton load at these
pressures.V
pressures.Various
arious parameter
parameter at 70kg/cm2 will be
be as follow
fo llow
• Load = Cross-sectional area o f cylind er X working pressure
cylinder
W = D2 X 4 X P
35000 = D2 X 0.785 X 70
D = 25.238 cm
Pump capacity = Cross-sectiona cylinder X speed
Cross- sectionall area of cylinder
Q = D2 X X V
4 Where:
= (25.238)2 X
X 160 W = Load (kg.)
4 D = Inside diameter (cm)
= 80001.25 cc per min.
min.
P = Working pressure (kg/cm2)
80 litre
litre per min. V = Velocity of cylinder (cm/min)
Q = Pump discharge (cm3/min)
PXQX100 = System efficiency in percentage
Power of
o f electric
electric motor
motor (kw) =
612 X 
70X80X100
= = 11.4
612 X 80
• Hence at 70kg/c2 working
wo rking pressure ID of cycle will
will be 25.238cm,
25.238 cm, pump capacity will be
be 80
LPM, and power of electric motor will be11.4 kw.

Khan 10-4
• For 200kg/cm2 working
wor king pressure, inside diameter
diameter of cylinder
cylinder and pump capacity
capac ity will
will be
D = 149.308 cm
Q = 28 LPM
Power of electric mot
motor
or remain same.
2
• For 350 kg/cm working pressure, inside diameter of cylinder and pump capacity will be:
D = 11.287 cm2
Q = 16000.98 cm3/min
or 16 LPM
Power of
o f electric motor remains the same.
• CETOP is an international standard for standardising

standardising hydraulic
hydraulic component. It specif
spe cifies
ies mounting
dimension
dimension and oil port. Fo r 16 LPM flow we select smallest
smallest series
s eries of CETOP standard
st andard valves,
that is CETOP-01 series valves.
valves.
• For 28 LPM we select CETOP-03 size of valves and for 80 LPM we select CETOP-6
size of valves.
• As on today
tod ay that is 26 th May 2008, cost of
o f various
various components are as follow:
follow:
2 2 2
Working 70 kg/C 200 kg/C 350 kg/C
pressure
Sr.
Sr.
Componets Make Model Cost Make Model Cost Make Model Cost
No
Motor Hindustan 15 HP Rs Hindustan 15 HP Rs Hindustan 15 HP Rs
1. Motors Vertical 21497/- Motors Vertical 21497/- Motors Vertical 21497/-
PVR- Rs 2RCE-7- Rs Polyhydron 2R CE- 7- CC Rs

2. Pump Yuken Polyhydron
150-70 20070/- DD 15400/- 15400/-
Rs DPRH-10-3- Rs
3. Relife Valve Yuken BG-06 Polyhydron Rs Polyhydron DPRS-06-S-
3365/- 200 1220/- 400 700/-
4. Direction Control Yuken DMG-o6 Rs Polyhydron 4DL-10- Rs Polyhydron 4DC-1D-G- Rs

5500/- G10.S 1540/- 103 1540/-
Valve
HydraulicCylinder Hydro ID-250 Hydro ID-150 Hydro ID-120
5. (Dimension are Electric
Rs
Electric Rod-80
Rs
Electric
Rs
Rod-100 70000/- 25000/- Rod-80 15000/-
in mm) Machinery Stroke-500 Machinery Stroke-500 Machinery Stroke-500
Rs Rs 200 ltr Rs
6. Oil Tank Hydroteck 800 ltr 400 ltr
8000/- 6000/-
13000/-
Accessories Rs Rs Rs
7. 10000/- 6000/-
8000/-
Rs
8. Total Cost Rs Total Cost
80655/-
Total Cost Rs
143434/- 66155/-
From above example we found that system with high pressure are economical and
low pressure are costly.
With time the cost of component will change. But the difference of cost between smaller,
medium and large size will always be there. Hence in every era the high pressure compact
hydraulic system will be always economical than low pressure bulky system.
• With increase of pressure, size of equipment and cost reduces, but maintenance problem
increases. While at low pressure, size of equipment and cost increases. Hence pressure is
decided carefully considering various factors.
• In case of machine tools, the
t he load on hydraulic cylinders
cylinders are much less as compared to hydraulic
hydraulic
presse
presses.
s. If we select
select high
high workin
working
g pressur
pressuree for them,
them, and
and try to calcul
calculate
ate the dime
dimens
nsion
ion of hydrau
hydrauli
licc

Khan 10-5
cylinder,
cylinder, then
the n these dimensions may be less than 1 cm or only fewfew centimeters.
cent imeters. Such
S uch thin and small
cylinder
cylinder may not give sta
stabil
bility
ity and maintenance free operation,
opera tion, hence for machine tool, we generally
select low working pressure, that is between 50 to 100 kg/cm2.
• There is no hard and fast rule for selection of working
work ing pressure But in general we have following
range of working
wo rking pressure for various systems in industry.
industry.
Sr.
Sr.
Filed of application Range of Working Pressure
No
2
1. Injecton Moulding Machine 210 - 350 Kg/c
Pump 2
2. 210 - 350 Kg/c
3. Relife Valve 30 - 70 Kg/c 2

2
4. Direction Control Valve 70 - 300 Kg/c
2
5. HydraulicCylinder 40 - 250 Kg/c
(Dimension are in mm)
2
6. Oil Tank 140 - 250 Kg/c
2
7. Accessories 350 - 700 Kg/c
Above data based on o n general study and old trend of

o f industry.
industry. Nowadays most of manufactures
prefer,
prefer, and design
designss high
high pressure
pressure system
system..

Khan 10-6
10.5 Pressure Drop in Hydraulic System
The pressure
pr essure drop
dr op in hydraulic system is
is basically due to
t o resistance
resistanc e to flow.
flow. While
While over coming
co ming
this resistance energy is lost. This loss of energy gets converted into heat, which increases temperature
of working fluid.
fluid. Pressure
P ressure drop
dro p is an undesirable
undesirable phenomena, and following
following are the main causes of
pressure
pressure drop in a hydraul
hydraulicic circui
circuit.
t.
1) Decrease in pump efficiency:-
Pump effici
efficiency
ency decreases due to wear and teart ear of
o f it’s
it’s internal components, or due to rise in
temperature. High temperature increases clearance between pump casing and moving element, element,
through which high
high pressure oil
o il escapes back
back to
t o low pressure side. This cause pressure drop and
further increase in fluid temperature.
2) Throttling in valves:-
valves:-
Valves are designed as perpe r CETOP standard,
sta ndard, and oil hole in them are 6 mm, 11 mm,
mm, 22 mm
etc. These oil holes work like an orifice.
orifice. Whenever large flow passes through
thro ugh a small hole, the
velocity of fluid
fluid increases but pressure
pressur e drops.
dro ps. Similarly
Similarly when fluid
fluid passes through
t hrough hydraulic valves,
valves,
there is some drop in pressure due to throttling.
throttling.
3) Internal leakage
leakage in valve:-
Direction control
cont rol valve
valve has a sliding
sliding spool in valve
valve body. Due to constant
co nstant use
u se sliding
sliding contact
conta ct
area wears out.
out . As
As clearance increases internal leakage increases. When high pressure fluid leaks
leaks
through
throug h these clearances, it causes drop
dro p in pressure, and flui
fluid
d heating.
What we have described for direction control
co ntrol valves also hold good for all valves
valves with
sliding
sliding spool and poppet
po ppet and with metal to metal sealing
sealing arrangement.
arrange ment. (sealing by fine
fine clearance)
4 )Valves
)Valves with spring loaded poppet:-
popp et:-
Construction
Const ruction of some valves are such that whenever fluid
fluid passes through
thro ugh them, then
t hen it has to lift
lift
a spring loaded
loaded spool
spoo l or poppet or
o r steel ball etc. Whenever fluid
fluid pressure acts against such spring
force to over-come compression of spring spring then some energy is is lost and pressure drops. Such
valves are pressure
pressu re reducing valves,
valves, sequence valves, check valves,
valves, pilot operated
operat ed check valves,
relief valves etc.
5) Resistance to flow
flow through pipe line:-
Fluid experiences resistance to t o flow while passing through pipe line, joints and bends etc.
Hence there
ther e is pressure drop
d rop at
a t every joint and bend in pipe line.
line. While passing through pipe line
due to such resistance energy of fluid
fluid is lost and pressure drops.
drop s.
• Pressure
Pressure drop is studied
studied carefull
carefully
y and
and calcula
calculated
ted to ascertain
ascertain the heat
heat generation
generation in
in system,
system,
because
because pressure drop reduces the system
system effi
efficien
ciency
cy,, and heat
heat which
which get generated
generated damages
damages the
system. Hence special steps are taken
ta ken at design stage to control
co ntrol and keep both of them in safe
limit.
At every valve,
valve, joint, and bend etc. pressure drop
dr op could
co uld be calculated with help of technical
data available
available in
in design book. Once we get total
tot al pressure drop, heat generated could be calculated.

Khan 10-7
10.6 Calculation of Heat Generation In Hydraulic System
Heat generation due to loss of efficiency:-

 The purpose
purpo se of calc alculation
culation of heat generation in hydrauli
hydraulicc system is to find
find and use correct size
and specification of oil cooling system.
 A low capacity cooling system will will get overloaded,
o verloaded, and may not not be able to maintain temperature
within optimum temperature limits.limits. And a higher capacity
capac ity cooling system will be costly,
costly, and
a nd cooli
coo ling
ng
system itself will
will utilise more
more electric
e lectric power, and may be under utilised. Hence to have right cooli co oling
ng
unit, correct
corr ect estimation of heat generation
generat ion is necessary.
necessary.
 Hydraulic
Hydraulic systems are not 100% efficien efficient.
t. As a thumb
t humb rule we assume 80% 80 % efficiency
efficiency,, and we
assume that balance 20% input energy gets converted convert ed in to undesirable h heat.
eat.
So if we use 11.5 kw motor, moto r, then we assume that 2.25kw (That is 20% of 11.5KW) will
get converted
co nverted in to heat. So our cooli coo ling
ng system should be able to extract 2.25KW of heat from
hydraulic system.
For extracting
extract ing 2.25kw heat, w e rrequireequire 0.799 TR capac
capacityity cooling
cooling system as per following
following
calculation.
2.25 (kw) X 860 = 1935 kcal/hr.
1935
= .06398 TR (Ton Refrigeration)
3024
If we assume 80% efficiency
efficiency of cooling system, then 20% more
mor e capacity is to be added
adde d in cooling
capacity
0.6398
= 0.7997 TR
0.8
Heat generation due to t o pressure drop:-

 Second
Seco nd method of finding
finding amount of generatedgenerat ed heat in system is is by calculating
calculating amount of
pressure
pressure drop in system
system.. The
The energy
energy lost in in form of pressure
pressure drop get converted
converted in to heat.
heat.
 Example: Considers
Co nsiders a hydraulic system with following specificatiospecification. n.
1) Motor
Motor HpHp = 15 Hp or 11.5 kw
2) Capacity
Capacity low flowflow and
and high
high pressure pump = 20 LPM
3) Capacity
Capacity of hihigh flow
flow and
and low pressure
pressure pump
pump = 70 LPM
4) System should have have foll
followin
owing g special
special features.
features.
a) Pressure will
will be
be held inin cylinder
cylinder by using
using pilot
pilot operated
o perated check valve . System will will also
also have
flow control
contro l to have variabl
var iablee and contro
co ntroll
lled
ed speed
spe ed while pressing. System
Syst em will
will always have fullfull and
maximum
maximum approach and return speed. spee d.
b) The detail
detail of compone
component nt used,
used, and
and hydraul
hydraulic ic circui
circuitt diagram
diagram to fulfi
fulfilll above
above menti
mentioned
oned
requirements are as per sketch No.___
Solution:-
 To calculate
calculate total
t otal pressure drop, we have to calculate, pressure dro p in pipelin pipeline,
e, pressure
drop in hydraulic valve,
valve, and pressure
pres sure drop
dro p in cylinder
cylinder due to sealse al friction.
friction.
 Pressure
Pressur e drop
dro p in pipe
pipe line could be calculated by using monog monogram/graph
ram/graph
 In present
prese nt example we are using standard
sta ndard pipe with 24mm inside inside diameter, and 33.4mm
33. 4mm outside
2
diameter. Pressure drop in pipe will be 0.1 kg/cm per meter for flow of 100 LPM (As per
monogram). We assume that total t otal length ofo f pipe line
line will be 10 meter.
met er. Hence approximately
appr oximately total
2
pressure
pressure drop in pipe lineline will
will be 1Kg/cm
 Manufacture of hydraulic pumps and valves provides complete technical detail in their catalogue,
including
including pressure drop at various
v arious pressure and flow. flow. So as per out working pressure and flow flow we
can find
find pressure
pressu re drop from catalogue
catalogu e of respective valve and pump

Khan 10-8
 Pressure drop in hydraulic cylin

cylinder
der is due to seal
s eal friction.
friction. Loss o f energy to overco me seal
friction is calculated aass follow.
12
9
7 8
5
4
10
P 11
2
1
Sr.No. Components Make Make Detail and Pressure Drop

1 Piston pump Polyhydron 2RCE7DD ---
2 Vane-pump Yuken PVR-150-70 ---
3 Unloading valve Polyhydron PPRU ---
4 Check valve Polyhydron C-30-S-1 Pressure drop 2kg/cm 2 at 100 LPM Flow
5 Relief vlave Polyhydron DPRS-10-S-315 ---
6 Direction control valve Yuken DSHG-06-3C60-A240 Pressure drop 2kg/cm 2 at 100 LPM Flow
7 Pilot operated check valve Polyhydron CI-30-S Pressure drop 2kg/cm 2 at 100 LPM Flow
8 Flow control valve Polyhydron 2PF-H-10-C-32 difference.5kg/cm2
Minimum pressure difference.5kg/cm
9 Direction control valve Yuken DSHG-06-2B2A-A240 Pressure drop 6kg/cm 2 at 100 LPM
Cracking pressure-5kg/cm2
10 Check-valve Polyhydron C-30-S-4 Pressure drop 6kg/cm 2 at 100 LPM
Cracking pressure-5kg/cm2
11 Return line filter Hydax RLF-10-25 With clean oil not pressure drop.In clogged
condition inbuild check valve open at 5kg/cm2.
We assume 2kg/c2 pressure drop at normal
working condition.
12 Hydraulic cylinder Hydro ID =280 mm Pressure drop 5kg/cm 2
Electric R od =170 mm
Machinery Stroke =500 mm
mm

Khan 10-9
 Total pressure drop at fast speed and low pressure will be.
be.
2
2 kg/cm - cracking pressure o f check valve
valve (1)
2
2 kg/cm - main direction
direction control
co ntrol valve (6)
2
2 kg/cm - pilot operated check valve (7)
5kg/cm2 - hydraulic cylinder
cylinder (12)
2
2kg/cm - direction
direction control valve
valve to control
co ntrol flow
flow (9)
2
6kg/cm - check valve to develope back pressure to operated direction control valve
valve (10)
2
2kg/cm - pressure
pressur e drop in return line
line filter
filter (11)
21 kg/cm2
 Total pressure drop at low speed
spe ed and high pressure will bebe
2
2kg/cm - cracking pressure of check valve (4)
2kg/cm2 - cracking pressure of
o f pilot
pilot operated
o perated check valve
valve (7)
5kg/cm2 - pressure drop across
a cross flow control valve (8)
2
5kg/cm - pressure drop due to
t o seal friction
friction in cylinder
cylinder (12)
14 kg/cm2
 After calculating
calculating total pressure drop
dro p heat generation
ge neration is calculated
calculated using followin
following
g equations.
equat ions.
10X60XPXQ
H=
427
Where H = Heal in Kcal/hr
P = Pressure drop kg/cm2
Q = Flow of pump in lpm
1 Kw/hr = 860 Kcal

1 Kcal = 827 Kgm
3024 Kcal/hr = 1 TR (Ton refrigerator)
10X60X21X90
 In present example
example heat generated
generat ed is = =2655.7kcal/hr
427
For removing 2656 kcal/ hr heat we need =


3024 = 0.878 TR Capacity cooler
 If we assume cooler
coo ler effici
efficiency
ency as 80%, then
t hen we should selected cooler
co oler capacity as
0.878
= X100 = 1.097TR
80
This calculation
calculation is based
based on heat generation
gener ation at high speed and low pressure operation.
ope ration. But system
also operates for some time at low speed and high pressure in which
which case heat generation is low.
low.
Hence actual
act ual heat generation will be less than 1.097 TR.
1 TR is standard capacity of cooler,
coo ler, hence
hence we will
will select 1 TR Air-cooled
Air-cooled oil cooler (chiller)
(chiller) in our
system.
 Another equation
equa tion which could be used forfor calculating capacity of water coo ler is
is
m x s x (t1-t2) X 60 = H (kcal/hr)
Where m = mass of fluidfluid (LPM)
S = specific heat of fluid.(it
fluid.(it is 1 for water and 0.85 for mineral
mineral oil)
t1-t2= Temperature difference of fluid before and after cooling.

Khan 10-10
10.7 Sequence
Sequence and Cycle Diagram
Very few power packs are operated by hand. hand. Most of the power
po wer packs are controlled
and actuated
actuat ed by electrical control panel. Press design, hydraulic
hydraulic circuit design,
design, hydraulic power
pack manufacturin
anufacturing,g, assembl
assembly y and testing,
testing, commi
commississionin
oning,g, and maintenanc
maintenance,
e, all
all these jobs are
done by different
different engineers. For better
bet ter comm
co mmunication
unication and understanding among them there should
be some
some bluepri
blueprint
nt which
which all
all should
should read, understan
understand d and interpr
interpretet without
without any diff
differe
erence.
nce.
Hence for this purpose along with circuit
circuit diagram, sequence chart and load cycle diagramdiagram
is also
also made. Sequence
Sequenc e chart contains,
cont ains, sequence of energisation of various solenoid, and their
controll
contro lling
ing parameter. Whil
Whilee load cycl
c yclee diagram indicates
indicates stroke
s troke,, load developed and tim
t imee required.
requ ired.
An example of sequence chart and a nd load cycle diagram for a deep drawing press is as
follow.
Pressure switch
15
4 PS1
13
12 LS
11 1
Limit LS 3
switches
LS 10
2
Blank-hilding
cylinder
S2 S3 S
8 4 9 S5
S1
Unloading
valve 6
4
15 16
P V M 15
14LPM 70LPM 15
250BAR 20BAR 15HP
16
17
Figure No. 35.25
Hydraulic Circuit Diagram of Deep Drawing Press
Operation of Deep drawing Press: -

1. Pres
Presss has four
our blank-
ank-h
holdi
oldin
ng cyl der 13 and a main pressing cylinder 12. Four blank-holding
cylinder
cylinder operate d by a common solenoid-operated direction control valve4, while main
cylinder operated
cylinder
cylinder operated co ntrol valve8.
oper ated by another direction control

Khan 10-11
2. Two pum
pumps areare use
used d in whi
which low pres
pressusure pump2 is unload
re pum unloadeded by unloading valve, which
5
is actuated, and control
contro l by a solenoid
solenoid valve
valve . (S1)
3. For deep
deep draw
drawiing operati
operation on shee
sheet-m
t-metal
etal blank
blank is place
placed d on press-
press-tab
tablele manual
anuallly. On
pressi
pressing
ng push-bu
push-buttontton blan
blank-h
k-holdi
olding
ng cyl
cylinder
inder moves
moves forward
forward,, and presses
presses the sheet-m
sheet-metal
etal
blank.
blank. Load
Load isis sensed by pressure switch (PS1), which gives gives signal
signal to main
main cylinder
cylinder to
take its forward stroke.
4. The depth
depth of drawdraw produc
produceded by
by forwa
forward rd stroke
stroke of mai
mainn cyl
cyliinder
nder is
is sens
sensed
ed by
by (Lim
(Limit
switch) LS2, and this this stops forward stroke
st roke and activate return stroke.
5. Compl
Completietion
on of return
return stroke
stroke is sensed
sensed by limi
limitt switch
switch LS3 and it stops return
return stroke
stroke and
and
activate return
ret urn stroke
str oke ofo f blank-holding
blank-holding cylinder.
cylinder.
6. Return
Return stroke
stroke of blank
blank-hol
-holdi
ding
ng cyl
cylin
inder
der is
is sens
senseded by limi
limits
ts swi
switch
tch LS1.
LS1. It stops
stops the
the return
return
stroke of blank-holding cylinder.
7. Eject
Ejection
ion is automa
automati ticc and
and achi
achieved
eved by mecha
mechani nical
cal mean
means.s. Linka
Linkages
ges are
are provi
provided
ded by
by whi
which
ch
the returning
ret urning platen of blank-holder
blank-holder also eject the drawn component.
component . Drawn component
removed manually and new blank-loaded manually. This makes press ready for next
operation.
Sequence of Operation Chart
SEQUENCE OF S1 S2 S3 S4 S5 CONTROLS/
OPERATION ACTUATION
ACTUATION BY
Start of Cycle
ON OFF OFF ON OF
OFFF Push-botton
Blank-holding Cylinder
Cylinder
Forward Stroke (Manual)
Main Cylinder ON ON OFF OFF OF

OFFF PS1 (Presure switch)
switch)
Forward Stroke
Main Cylinder
Return Stroke ON OFF ON OFF OF
OFFF LS2
Blank-holding Cylinder
Cylinder ON OFF OFF OFF ON LS3
Return Stroke
Completion of
ReturnStroke and End of OFF OFF OFF OFF OF
OFFF LS1
Production
Product ion Cycle
Cycle
Note : S1, S2,S3, S4, S5

S5 are Solenoid
Solenoid electrical
electrical coil of valve
valve No.5, 8, 9
Note: - A simpl

simplee control
contr ol panel uses contactor,
co ntactor, push-button
push-butto n etc.for
etc. for actuation
actuat ion of solenoid coil when
control
contr ol instrument such as limi
limitt switch, pressure-sw
pr essure-switch
itch etc. get actuat
ac tuated
ed they give signal
signal in
in control
panel.
panel. And because
because of which
which as per the wirin
wiringg and design
design of panel
panel, one
one solenoi
solenoid d get switche
switchedd off
and other switch on.

Khan 10-12
Cycle Diagram: -
,
g
n
i
s
n
e .
s p
e
r m
u
s u
s p
r e
e r
p u
c s
i s
l e
r
u
a p
r
d w
o
y l
H f
)
l o
a g
d c i
i n d d d
e
t r d
t e
t e
t e
t
a c a a a a
u
t e l
l o u
t u
t u
t
c c c c
A - n
E u A A A
1 n d 2 3 1
o n S S S
S N
P ( A L L L
n g
n
0
0
7 w r a w i
d
S l o
o
F
r
e
a
s
d h t
n
i o c
r
e
l r t
y p u
c a p
r
n
n e
i
a
k
o i d
r
t a p
M S R
0
r Blank holding

e 0
d 0
n
i
5
l
y
R
e v
c
g
d
r
e r
a
s e
n
i
d
w
r
l o
o e F
h k
k o
r
n t
a
l S
B
0
Time
Time Cycle complete
Cycle
Figu
gure
re N
No
o. 3
35
5.26

Khan
10-13
10.8 Circuit Diagram For Modular Type

Type Power Pack: -
Modular valves are
ar e most widely used in indust
industry
ry because of o f convenience in using them.
They do not require compl
co mplicated
icated manifold block
block and piping. To represent the way and sequence
in which
which they have been stac
stacked
ked one above
abo ve the other,
ot her, while assemblylin
assemblyling g a hydraulic system, their
circuit diagram
diagram is slightly modified.
modified. We briefly explain it as follow
fo llow..
Direction controll valve (4) 2

6 Relief valve for pump (3)
Pilot operated check valve (6)
Flow control valve (5)

5 Return line filter
A Manifold
Oil filler B block
breather
4 Tank
1
3
2
P M
1
Example of a Modular Valve stacked
Figure No. 35.22
Figure No. 35.21
Above mention circuit is general hydraulic circuit
circuit diagram. For modular valve same above
circuit can also be drawn in following
following ways.
A-port
B-port
P A
Direction control Direction
Pipe line valve (4) control
T B
valve (4)
Tank line
Flow control Relief valve (3)

valve (5)
Pilot opareted
Check valve (6)
Check valve
Relief valve
for Pump (3)
P P Manifold or Flow control

T sub-plate valve (3)
T
A
A- Mani-
B-r t
po
B po r t Tank
Cover
Cylinder Pump (1) Tank
Pump
line line
Figure No. 35.23

Khan
10-14
Some of the logic and feature of making

making such type of circuit is as follow
follow..
1) As a commo
common n pump
pump line
line and
and tank
tank line
line drille
drilled
d throug
throughh mani
manifol
fold
d for
for numb
numberer of
of sole
soleno
noid
id valve
valves.s.
Hence a corresponding two straight horizontal lines are drawn as pump & tank line in circuit
diagram.
2) In case
case of
of modu
modularlar valve
valve,, all the
the valve
valvess have
have same
same hole
holess namel
namely y, P-(Pum
P-(Pump),p), T-(Tank
-(Tank),), A&B
A&B
(both port of cylinder), As per international standard these holes of all the valves have same
dimension,
dimension, and perfectly
per fectly match each
ea ch other when staked one above the other. When valve stacked
one above the other, four vertical pipe like passage forms. Oil passes through all the four line of
all the valves, irrespective of whether valve requires those line or not. Hence we have drawn
four vertical lines.
3) As Pump
Pump line
line (P) and Tank line
line (T) starts
starts from
from Pump
Pump andand Tank
Tank and mostly
ostly passe
passess throug
through h
direction control valve and ends at actuator (Cylinder or Motor). Hence out of four vertical lines
two starts from Pump, Tank passes through direction control valve and ends at A and B-port of
cylinder.
4) Hence
Hence two horizo
horizontal
ntal and four
four vertic
verticalal lin
lines
es are com
common
mon featu
feature
re in
in this
this type
type of circ
circui
uitt
diagram.
5) As per
per valve
valve adde
addedd in circui
circuit,
t, thei
theirr graphi
graphicc diagram
diagram drawn
drawn bet
betwe
weenen corres
correspopond
ndin
ing
g six
six lines
lines..
6) For
For bette
betterr under
understan
standi
ding
ng a dotte
dottedd line
line is draw
drawn n for
for mani
manifo
fold
ld and valve
valve.. Each
Each dotte
dotted
d bloc
block
k
indicates one unit of valve or manifold (sub-plate).
7) We have
have drawn
drawn abov
abovee circui
circuitt diag
diagram
ram for
for one
one valve
valve bank
bank (set
(set of
of a valv
valve)
e).. More
More num
number of
valves bank could be added on manifold, using same pump and tank. If a relief valve, pilot
operated check valve, flow control valve and direction control valve is further added to operate
one more cylinder in same power pack with common pump and motor, then new circuit diagram
will be as follow.
Second Valve Bank First Valve Bank
Direction controll P A P A
Direction controll
valve
valve
T B T B
Flow controll Flow controll

valve valve
Pilot opareted Pilot opareted

check valve check valve
Relief valve Relief valve

for pump for pump
P P Manifold or
T
T
B B
A A
Tank New Cylinder Cylinder Pump
Figure No. 35.24

Khan
10-15
10.9 Use of filter in Hydraulic Circuit:-

Circuit:-
A hydraulic circuit could
cou ld be designed in five ways to filter oil in system.
1) Circuit with suction stainer:-

In this design a filter
filter is provided
pro vided at suction
su ction side of pump. Advantage
of this design is that it prevents
preve nts entry of o f large size contamination
contamination in M
system. Which may may cause immediate
immediate and severe se vere damage to system.
Disadvantage of this design is that fine filter could not be used at
suction side as thist his may result in high pressure drop dro p in suction, which
will cause cavitation in pump. Generally 150 mesh size filter which
can filter
filter upto 100
10 0 micron size particle are used in suction stainer sta iner..
2) Circuit with disch discharge
arge line or returnreturn line filter:-
In this design the oil exhausted to tank are filtered. filtered. Advantage of this
design is that it can tolerate high pressure drop dro p as compared to suct suction
ion
stainer, so the
t he filter
filter with filtering capacity of 10 micron could be used.
Disadvantage of this design is that some valves such such as proport
pro portional
ional
M
or servo valve require less than 5 micron cleanliness. If we use 5
micron
micron filter
filter at return line then it wil w illl cause excessive and constant const ant
back-p
back-press
ressure
ure which
which is undesi
undesirab rablle. He
Hence
nce fine
fine filteri
iltering
ng elem
element
ent could
could
not be used in return line line filter.
filter.
Suction stainer
sta iner and return line line filter
filter do have some disadvantages, but
because of protection they provide to the system, system, they are almost almost
compulsory part of all hydraulic circuit.
3) Circuit with pressure line filter:-
For absolute
abso lute cleanliness
cleanliness of oil pressure line line filter
filter is used. But use of o f
this filter
filter causes excessive pressure pre ssure drop
dro p in system.
system. M
4) Pressure line bleed-off filters:-
Suction stainer
st ainer,, return
retu rn line
line filter
filter or
o r pressure
pressur e line fil filter
ter are selected as
per pump capacity
capacity of system.
system. For very high high capacity pump, vary
large capacity of fil filter
ter is required, which w hich may be vary costly. costly. For
simple
simple economical
econo mical system, and those t hose system, where involvement of
contami
conta mination
nation is very less, pressure line line bleed of type circuit is used.
In this system through
throu gh an orifio rifice
ce a small quantity of oil is discharged to
tank through
t hrough filter.
filter. Advantage of o f this system is that a small size size filter
be used in the filte
filteri
ring
ng system
system.. Disadv
Disadvan antage
tage of this
this system
system is that the M
oil passing through
thro ugh orifi
or ifice
ce for filtering is lost lost from the effective pump
output.
5) Independent filtration circuit:-
This type ofo f circuit is also called kidney loop or o r off line
line filtering system.
In this system a separa
separate te pump is used to filter filter oil
o il.. Generally forfor large
and critical hydraulic system this is used. The fluid fluid which is circulated
by independen
independentt pump pump for fil filtration may also also pass
pass through cooler to
maintaining
maintaining temperature
temperatu re of o f fluid.
M
M

Khan 10-16
10.10 What is Pumping Unit and Powerpack Unit?

In case of huge machinery like like steel rolling
rolling plant etc where more number o off hydrauli
hydraulicc actuato
ac tuator r
and control of hydraul
hydraulicic actuator are used, system could be designed designed and made in in two ways. In
first
first method the control
co ntrol and manifold
manifold block
block of each actuator couldco uld be placed very near to actuator
actuato r
(which may be a cylinder and motor) mot or).. And
And pump and moto mo torr which are common
co mmon to all manifold
manifold are
place
placed d at long
long dista
distance
nce at some
some suitab
suitable
le place
place.. As in this
this case
case motor,
motor, pump,
pump, relie
relieff valve
valve and
and reserv
reservoi
oir
r
assembly supply only oil to all the manifold
manifold block. And do no control contr ol each actuat
act uator.
or. Hence they arear e
called as pumping unit
In pumping unitunit we have few advantages such as:
Length of pipe between manifold
manifold block and actuator
act uator are less and hence less cost co st of piping, less
possibi
possibili lity
ty of leakage,
leakage, less problem
problem of spongines
sponginesss and compressi
compressibi bili
lity
ty of oil ete.
While
While in power pack design,
d esign, manifold
manifold block and valves of all actuators
actuato rs are mounted on o n single
oil reservoir. And
And from manifold
manifold block long pipingpiping are laid
laid to all the actuators.
actuat ors.
Power
Powe r pack type of design also have some advantages over pumping pu mping unit,
unit, such as maintenance
maintenance
of hydraulic
hydraulic equipment is is easy.
easy. Because of o f more number of long piping piping heat ofo f oil
oil get dissipated.
We get more space around ar ound actuato
act uator,r, as control
contro l unit
unit (manifold)
(manifold) is on reservoir etc.
Control units
Actuators
Motor and Pump assembly
Oil Tank
Pumping Unit
Control units
Actuators
Motor and Pump
assembly
Oil Tank
Power pack unit

Khan 10-17
Study of Hydraulic Circuit Pressure Control Circuit
10.11 Pressure Control Circuit
1. There should
should be alw
alway
ayss a relie
relieff val
valve
ve to control the maxi
maximum
mum pressure
pressure of the system
system..
Relief valve should be immediately
immediately after pump, so that
t hat due to any
a ny reason if oil flow
flow generated
generated
by pump gets blocked
blocked then it can pass through relief
relief valve,
valve, without
without damagin
damaging g any other
parts of the system
system..
Pressure relief valve
P M
Figure No 10.11.1
2. When
When two pumps
pumps are usedused in
in a system
system in which
which one
one pump
pump is
is with
with high
high flow
flow and
and low
low
working pressure for fast approach
appro ach and return speed, and second pump
p ump is with
with low flow
capacity and high
high working pressure
pres sure for actual pressing
press ing operation.
operat ion. Then after reaching
certain pressure high flow
flow pump is required to be unloaded to tank to avoid excessive
excessive load
on prime-mover. For such application “Unloading type relief valve” is used as shown in
following circuit diagram.
Oil at low pressure to hydroulic system
Figure No 10.11.2
Main relief Valve

Valve of
system
Pilot opereted unloading
P M P relief Valve
High Pressure Pump

Low Pressure Pump
High pressure oil to system for pressing operation.
High flow and low pres-

High pressure sure pump discharge
piolt
piolt Line Pilot opereted unload- unloded to tank
ing relief
r elief Valve
Valve through unloading re-
lief Valve
P M P
Figure No 10.11.3
Hydroulic circuit diagram when unloading valve got actuated

act uated

Khan 11-18
Study of Hydraulic Circuit Pressure Control Circuit
In a hydraulic
hydraulic circuit when different
different pressures are required at different
different stage of
o f operation, then
t hen
following
following type of
o f arrangement of direction control
co ntrol valve and pressure relief valve could be used.
If pressure
pressur e setting
set ting of ‘Pressure
‘Press ure Relief Valve-A
Valve-A’’ and ‘Pressure Relief
R elief Valve -B’ are lower than
system pressure,
pressur e, then when solencid-1
so lencid-1 is energized,
energized , then maxium pressure in system will will be as per
Pressure
Press ure Relief Value
Value -A and when solenoid-2
solenoid- 2 is energized then
the n maximum
maximum pressure
pressu re in system will
be as per Pressure
Pressure Relief
Relief Valve-B
alve-B.. And when
when both the solenoi
solenoids
ds are switched
switched off then maxi
maximum
mum
pressure
pressure wil
will be as per setting
setting of relief
relief valve-C
valve-C.. Unloadi
Unloading
ng reli
relief valve
valve D in circui
circuitt 35.2 will
will only
only
control pressure of low pressure pump. (Fig 35.2)
Pressure requires as per Pressure requires as per Pressure requires as per

setting of pressure relief setting of pressure relief setting of pressure relief
valve valve valve
C B A
Sol. 2
A
Sol. 1
C D
High pressure
pilot Line
P M P
Figure No. 10.11.4

Hydroulic
Hydroulic circuit diagram when unloading valve got actuated.

Khan 10-19
Study of Hydraulic Circuit Pressure Holding Circuit
10.12 Pressure Holding Circuit

(By using pilot
pilot operate
o perated
d check valve)
Many time
time hydraulic
hydraulic presses are required
requ ired to hold
ho ld the job under compression for very long
period
period of time.
time. For
For such operation if motor
oto r runs continuously
continuously to develop
develop pressure
pressure for pressing
pressing
operation
operat ion then it will bebe uneconomical
uneco nomical,, due
d ue to excessive electric consumption. Also oil will will get
heated up,
u p, as most of the pump
pu mp discharge will
will pass through
thro ugh the relief valve.
valve.
For such application
application pilot
pilot operated check valve is used in circuit.
circuit. Which hold the pressurized
oil in cylinder
cylinder or
o r system
syste m for
for long
lo ng time. A simple circuit of this
t his type is as follow.
fo llow.
There should not be

Pressure held in any pressure in pilot
cylinder
cylinder in neutral line of pilot operated
position check valve. Otherwise
pressure not be held in
system.
Pilot operated Check valve
P M
Figure No 10.12.1
Pressure held in cylinder at neutral

ne utral position.

Khan 10-20
Study of Hydraulic Circuit Pressure Holding Circuit
For return
retu rn stroke-pilot
stroke-pilot pressure is
given to unlock the pi
pilot
lot operated
oper ated
check valve and release pressure in
cylinder
P M
Pressure
Pressur e released from cyli
cylinder
nder for return
retur n stroke.
Figure No 10.12.2

Khan 10-21
Study of Hydraulic Circuit Decompression Circuit
10.13 Decompression
Decompression Circuit
This is a feature of hydraulic circuit. When high pressure

pres sure fluid is held in cylinder,
cylinder, and when
this high
high pressure is suddenly
sudde nly released, then a surge
su rge of
o f large
large volume of fluid
fluid passes thro ugh the
pipel
pipelin
inee and produces
produces a banged
banged sound and vibrati
vibration.
on. Sudden
Sudden release
release of stresses
stresses also
also cause
cause Jerk
Jerk in
in
press-bod
press-body y. To avoi
avoidd this,
this, pressure
pressure is slowl
slowlyy reduced
reduced to mini
minimum
mum possibl
possible,
e, then cylin
cylinder
der allowed
allowed
to retract.
ret ract. This
T his feature of
o f slow
slow release
re lease of high
high pressure
pressur e in system is called
called decompression.
For Decompression four types of circuits are used.

a. Decom
Decompr
pres
essi
sion
on circ
circui
uitt usi
using
ng an orif
orifice and
and ch
check
eck val
valve
ve..
b. Decompr
Decompress
ession
ion circui
circuitt usi
using
ng orifi
orifice and solenoi
solenoidd operated
operated directi
direction
on control
control valve.
valve.
c. Decompr
Decompress
ession
ion circui
circuitt usin
using
g valve
valve which
which have
have in-b
in-bui
uild
ld feature of decompress
decompressiion.
d. Decom
Decompre
press
ssiion by
by dire
directi
ction
on control
control valve
valve (slow
(slow move
movemementnt of its spool
spool).
).
a) Decomp
Decompre
ressi
ssion
on circuit
circuit using
using an
an ori
orific
ficee and
and che
check
ck valve.
valve.
In following circuit
circuit diagram
diagra m when pump develops pressure,
press ure, no oil will
will flow through
throug h check
valve. Only in neutral position of solenoid operated direction control valve, pressurized oil of
cylinder
cylinder will slowly
slowly press over check valve to tank.
t ank. Due to
t o orifice the release o
off pressurized oil
o il will
will
be very
very slow.
slow. This
This arrange
arrangem ment cannot
cannot be used when there
there is alway
alwayss a pressure
pressure in pump
pump line.
line. (Fig.
(Fig.
No. 35.4)
Check valve and

orifice
orifice for decom-
dec om-
pressi
pression
on
P M
Figure No 13.1

Khan 10-22
b) Decompression circuit using orifice and solenoid operated direction control valve.
When there is always

always a pressure
pressur e in system,
system, then above
abo ve mentioned arrangement cannot be
used. In such case
cas e a direction control
cont rol valve in place of check valve is better
bett er alternative.
alternat ive.
In following
following circuit when two-way-two
two -way-two-position
-position solenoid
so lenoid valve
valve is energies, it releases oil
o il
to tank.
t ank. Due to orifice
orifice there will
will be
be gradual drop in pressure. (Figure No. 13.2)
Valve for De-

compression
Feature
P M
Figure No 13.2
(Pressure held in first
first cylinder
cylinder is getting
gett ing De-compressed)
Status of Pressure in Neutral Position
Position after forward stroke

Khan
10-23
c. Decompr
Decompress ession
ion with
with in-buil
in-buildd featur
featuree in valves:
valves: -
Pilot operated
oper ated check
che ck vale, pre-fill valves etc. can also have decompression
deco mpression feature in their
basi
basic desi
design. When
When such
such valve
valvess are used,
used, they automa
automatitical
cally
ly reduce
reduce pressur
pressuree gradual
graduallly. Detai
Details
of such valve have been described in chapter
chapter No. 31.
d. Decompr
Decompressi
ession
on by directio
direction
n control
control valve:
valve:
Finit Position
Spool
Spoo l of direction
direction control
cont rol valve
valve changes
its position from one finite
finite condition to another
a nother
in fract
fraction
ion of a second. In tra
transit
nsit condition the
pressuri
pressurized
zed port may get connected
connected to tank as
explained in following figure. This causes a
sudden drop
dro p in pressure resulting in large sound Transite position in which
and vibration. all port are connected to tank.
Figure
Figure No 13.3
To avoid this situation,

situation, a pilot
pilot operated check valve
valve could be used to hold ho ld pressure in
system when solenoid operated valve is changing position, and then decompress the pressure by
three methods
method s discussed earlier.
Second method to reduce the sudden fall of pressure is is to move spool so slowly that
pressure
pressure drops slowl
slowly y. Some type
type of solenoi
solenoid
d valves
valves have
have in-bui
n-built
lt features
features to move
move spool slowl
slowlyy.
In case of pilot operat
operated
ed solenoid valve without
without in-built
in-built decompression feature, a thrott
t hrottle
le
cum check valve is is used between pilot valve and main direction control
cont rol valves
valves for decompression
deco mpression
purpose. Throttle cum check valve valve controls the flow
flow of oil in pilot
pilot lin
linee to main
main direction
direction control
valve, which shift
shift the spool.
spo ol. Reduced
Reduc ed oil flow
flow in pilot line
line slows down the t he movement of spool
spoo l
results in slow fall of pressure in system.
Throttle cum check valve reduces

r educes
the flow of oil in pilot line to
main direction valve, resulting is slow
shifting of spool
Pilot line to main

Direction control valve
Pilot valve
Main Direction
control valve
Orifice
Back pressure get
developed
develope d in system due
P M to orifice.
Figure No 13.4

Khan 10-24
Study of Hydraulic Circuit Hyd. Circuit with back pressure
10.14 Hydraulic Circuit with

with Back Pressure: -
A backpressure may be required in a hydraulic
hydraulic system to operate
o perate a pil
p ilot
ot operated
operate d directional
control valve.
For such
suc h back pressure ana n orifice
orifice or a check valve
valve is used, as shown in following
following circuit
diagram. Orifice
Orifice and check valve is is used just after
a fter high-pressure
high-pressur e pump while a check valve could
be used in return line
line of system
system also.
also. But
But when
when orifi
orifice
ce and check
check valve
valve is used, we cannot
cannot change
change
or vary the back pressure. For
Fo r accurately
accurat ely select and vary the backpressure special backpressure
backpressure
valve is used in return line, in place
place ofo f simple
simple check valve (Fig.
(Fig. No.
No . 35.9)
35. 9)
By using backpressure valve we can exactly vary and select the backpr essure. While by
using a check valve back pressure will be fixed
fixed and as per
p er the cracking pressure
pres sure of spring of check
valve.
Main directio
direction
n
Pilot Valve
Valve Opereted
Operet ed by
controll
cont roll Valve
Valve
Back Pressure
A B
P Y
Orifice
Orifice to develop
Back Pressure
P M
Figure No. 14.1

14. 1
Back pressure
pre ssure in system by using orifice.
orifice. In place orifi
o rifice
ce a check valve also
could be used.

Khan 10-25
An orifice
orifice should
shou ld always
always be used after
afte r a relief valve, so that if any dust particle
p article get struck
s trucked
ed
in orifice,
orifice, then
t hen build-up
build-up pressure will not damage
d amage the pumpp ump and system.
Main directio
dir ection
n
controll
contr oll Valve
Valve
Pilot Valve
Back Pressur
P ressuree Valve
Valve
P M
Figure No. 14.2

Back pressure
pr essure in system by using back pressure
pressur e relief valve
valve in return line

Khan 10-26
10.15 Back pressure

pressure in a hydraulic cylinder (Counter
(Counter balance circuit)
Suppose a heavy load is hanging

hanging from the piston rod. In such case in forward stro ke the
cylinder
cylinder may travel at higher speed than
t han speed possible
pos sible by
by pump capacity (discharge volume) of o f
system. In such case vacuum gets
get s created in cylinder,
cylinder, and oil starts
star ts evaporating,
evapo rating, resulting
resu lting in spongy
action of cylinder.
cylinder.
To avoid over running of piston rod under load, a back pressure is developed in the return port
of cylinder using counter balance valve as shown in following circuit diagram.
Back pressure
pressu re in system
system as per
setting of
o f Counter Balance Valve,
Valve,
which holds the load in position.
Check Valve
Valve for free reverse
rev erse flow
Counter Balance Valve
P M
Figure No. 10.15.1
Status
Stat us of pressure in
in natural position after
after forward stro ke.

Khan 10-27
Check-Valve
Check-Valve for free reverse
rever se flow
Passing oil after

after generating
g enerating
desired pressure
P M
Forward stroke
Figure
Figure No. 10.15.2

Khan 10-28
Check-Valve
Check-Valve for free reverse
reve rse flow
Load
P M
Figure No. 10.15.3

Reverse stroke

Khan 10-29
10.16 Hydraulic Circuit Using Sequence Valve

Consider a hydraulic
hydra ulic press, which has a job-holding or fixing
fixing clamp, operated
oper ated by hydraulic
hydraulic
cylinder.
cylinder. When
When press is operated,
oper ated, first clamp
clamp cylinder
cylinder is required to get actuat
a ctuated
ed and clamp the
component.
component . And
And after clamping
clamping component
compo nent at certain
c ertain pressure, main cyli
cylinder
nder is required to be
actuated
actuate d for pressing operation on
o n the component.
co mponent. By using a sequence valve
valve said requirement
could be economi
econo mically
cally achieved.
achieved.
Main Pressing Cylinder
Clamp
Cylinder
Sequence
Valve
P M
Figure No. 10.16.1

Forward
Forwa rd Stroke actuated
actu ated only for clampin
clamping
g cylinder
cylinder
In above circuit as soon

so on as solenoid
s olenoid valve
valve actuated.
act uated. First clamp cylinder
cylinder will
will clamp
clamp the
component, and after developing certain pressure and as per pressure setting
sett ing of sequence valve,
valve,
sequence valve will allow main cyli
cylinder
nder to
t o be actuated
act uated.. Hence a performance which was possibl
po ssiblee
by using
using a costly
costly directi
direction
on control valve
valve can be achieved
achieved by using
using a economica
economicall sequence
sequence valve.
valve.

Khan 10-30
Clamp Cylinder
Sequence Valve
P M
Figure No. 10.16.2

Forward
Forwar d Stroke
Strok e actuated only for main cylinder
cylinder

Khan 10-31
Clamp Cylinder
Sequence Valve
Make circuit for clamping

them pressure total two
P M
Figure No. 10.16.3

Status
Stat us of presure in
in neutral position after forward stroke
stro ke

Khan 10-32
Clamp Cylinder
Sequence
Valve
P M
Figure No. 10.16.4

Return Stroke

Khan 10-33
Study of Hydraulic Circuit Direction Control Circuit
10.17 Direction
Directi on Control circuit
Hydraulic Circuit For Actuating Number of cylinder with common Motor and Pump:-
When more than one cylinder is used in a system,
system, and
an d all the cylinders are required
requ ired to be
actuated
actua ted independently
independe ntly,, then more than one
o ne direction control
contr ol valve inin circuit is
is required. If the basic
basic
requirement of circuit is that when cylinders are not actuat
a ctuated
ed (in idle
idle condition), pump
p ump should be
unloaded to tank. And
And when cylinders
cylinders are actuated
actu ated then
t hen only pressure gets developed.
developed . This could
be achieved
achieved in number
number of ways
ways as follow.
ollow.
a. Usin
Usingg Ten
Tendu
dum m typtypee dir
direc
ecti
tion
on cont
contrrol valv
valvee in
in ser
serie
ies:
s: -
P M
Figure
Figure No. 10.17.1
Status
Stat us of pressure in neutral position after
after forward stroke.
str oke.
 This circuit could

co uld operate
oper ate each cylc ylinder
inder independently,
independently, but not simultaneously
simultaneously..
nd rd
 Working pressure
pre ssure ofo f 2 and 3 cylinder
cylinder will depend on the pressu
p ressure
re rating of first solenoid
so lenoid
valve
valve at its tank port.
po rt. (It is generally
generally 100 Kg/Cm²)
 As all the time oil passes from all the direction
direc tion control
co ntrol valve hence there
t here will be a pressure
pres sure
drop and oil heating, if pump of high discharge
discharge is used.
used .
b) Hydraulic
Hydraulic circuit to operate
operate more number of cylinders
cylinders using all-port-block
all-port-block valve
valve and
solenoid operated unloading valve.
 In this circuit all the cylinders
cylinders can
ca n have high pressure.
 When none-of the cylinder is actuated, unloading valve will unload pump discharge to tank.
When any solenoid operated
oper ated direction
directio n control
contro l valve
valve gets activated,
activated , solenoid valve of unloading
valve
valve should also be actuated
actuate d to develop pressure in system.
system.
 When lever
lever operated
opera ted direction control
co ntrol valves are used then addition direction control
contro l valve
valve is
used in place of unloading
unloading valve to unload thet he pump when not in used, and to develop
d evelop pressure
when required. Pressure
Pres sure developing direction control
cont rol valve is
is always operated
oper ated with all the
direction
direction control valves.
valves.

Khan 10-34
Study of Hydraulic Circuit Direction Control Circuit
1
2 3 4
When solenoid
valve no. (1) get
de-energised oil
passes to tank via
via
pil
pilot operate
operatedd P M
relief valve.
Figure No. 10.17.2

Status of pressure in Neutral
Position after forward stroke.
Oil passing
passing to tank
tan k at
atmospheric pressure
through
throug h this valve in
neutral position
1 2 3 4
P M
Figure No. 10.17.3

Status of pressure in Neutral

Khan 10-35
Study of Hydraulic Circuit Regenerative Circuit
10.18 Regenerative Circuit

This is special
special type of circuit, and named as regenerative circuit, because we re-us e the
exhaust oil
o il coming out from
fro m return port
po rt of cylinder while cylinder
cylinder is taking forward
forwa rd stroke.
stro ke. And
exhaust oil
o il along with pump discharge is supplied again to the t he cylinder
cylinder for its forward st roke.
roke .
Following circuit will explain its princi
pr inciple.
ple.
B
2
1
Oil from return port of

cylinder gets mixed with
main discharge of pump
through the check valve
1 No.2.
No.2.
2
(As oil passes
through check valve
No.2. There is some
pressure in system
system as
per cracking
cracking pressure
of check valve No.2)
P M
Figure No. 10.18.1

Forward Stroke
Stro ke at low
low pressure

Khan 10-36
Oil From B-Port

A passi
passing to tank
tank through
through
relief valve
valve No.2
No. 2 .
B
2
1
1
2
P M
Figure No .10.18-B
Forward stroke under pressure
Oil will
will not pass
pa ss through
throu gh check valve (2), because
becaus e there is higher
higher pressure
pr essure on
o n pump side.
side.

Khan 10-37
B 2
1
Oil will not pass

through check valve
valve
1 no.2, as pressure on
2 both side
side are same.
same.
P M
Figure
Figure No. 10.18-C
Return stroke

Khan 10-38
Pressure is locked
locked in for-
ward pipe line, Because
direction control valve
keeps the
t he oil locked in cyl- B
inder port in neutural po-
sition
P M
Figure No. 10.18-D

Status of Pressure in Neutral
 In re-generative circuit as all the oil exhausted from B-port combined

combined with pump disch
d ischarge,
arge,
and supplied to port-A. Hence cylinder speed will be more than the speed which could be
achieved by using only pump.
 If the cross-section
cros s-section area of ram is exactly half
half of the cross-section
cro ss-section area of cylinder.
cylinder. Then we
get same forward and reverse speed.
 As pump pressure increases,
increases, back pressure at B-port also increase. Due to higher
higher backpressure
the effective compressive load which cylinder
cylinder can develop
de velop get reduced correspondingly
corresp ondingly..
 To reduce backpressure many arrangements
arrangements are used.
u sed. Some
S ome of which are as follow.
follow.

Khan 10-39
a) When after
after dev
devel
elopi
oping
ng pres
pressur
suree cyl
cylinder
inder does
does not
not have
have to travel
travel any
any long
longer
er,, as in
in case
case of
coining, embossing etc. then an orifice
orifice provided
pro vided parallel to check valve reduces
reduc es the build-up
build-up
backpress
backpressure.
ure. But this
this also
also reduces
reduces forward
forward speed
speed slig
slightl
htly
y. Because
Because from
from return port some
oil escapes from orifice
orifice and returns
ret urns to tank
t ank (instead of
o f getting mixed
mixed with pump discharge).
Pressurised oil in this side escapes to tank

via throatle if movement of main slow
downs. (In fast forward motion as all th e oil
can not pass through throattle hence either
they get mixed with main pump flow or get
reliefed by relief valve No.2)
P M
Forward stroke under pr essure by very slow

slow movement
movement (for for coinin g forming)
Figure No 10.18-E

Khan 10-40
As very small quality of oil can pass

through throatle, hence maximum oil
A of return port gets mixed with pump
discharge and supplied to forward
stroke.
throatel
B
2
1
P M
Figure
Figure No. 10.18-F
Forward stroke
under pressure
pres sure and fast movement (before coini
co ining
ng and forming
forming operation)
o peration)

Khan 10-41
Regenrating circuit with unloading valve in return port of cylinder
1 2
P M
Figure No. 10.18-G
Forward stroke without pressure
(A-Port side of
o f piston
piston area is larger
larger than B-port side of piston area Hence a slight pressure on A
side develops high pressure ono n B side. Oil on high pressure gets
get s mixed
mixed with oil on lower
lower pres-
p res-
sure through check valve No.2)

Khan 10-42
b) In followi
following
ng circui
circuitt as
as soon as some
some pressure
pressure gets developed
developed at A-port, oil comin
coming
g out from
from
B-port gets unloaded to tank through
thro ugh unloading relief
relief valve. Hence backpressure gets
get s mini-
mini-
Unloading relief valve,

valve, releases oil
oil of
B-port to tank at low pressure
1 2
P M
figure
figure No. 10.18-H
10. 18-H
Forward stroke under pressure
(After
(After facing
facing resistance when pressure o f A-port side increased more than B-port side, oil stops
mixing
mixing through
thro ugh Check Valve
Valve No.2)
No. 2)
mized.
Khan 10-43
A
B 2
Relief Valve
Valve for B-p
1 2
Pressurised
Pressurised oil
o il of B-port under pressure
p ressure
gets
get s released to
t o tank via Check Valve
Valve
No.2
P M
Figure No. 10.18- I

Status of Pressure in Neutral
Position after forward stroke

Khan 10-44
P M
Figure
Figure No. 10.18-J
Return stroke

Khan 10-45
Study of Hydraulic Circuit Brake Circuit
10.19 Brake Circuit

When moto
motorr rotates
rotate s at a load. Even after the supply to motor
moto r switched off, due to inertia
of load motor
moto r keeps on rot ating. To stop the moto r following
following circuit may be used.
P M
Figure No. 10.19.1
Forward stroke.

Khan 10-46
P M
Figure No. 10.19.2
Reverse stroke.

Khan 10-47
Back pressure in
returen line of
motor.
Back pressure
valve
P M
Figure No. 10.19.3

Neutral
Neutral Positi
Position
on
Due to back-presure valve,

valve, motor faces a constant resisting pressure or force. This offers
offers resistence
resistence
to extra rotation
ro tation of moto
motorr due to inertia of rotating load.

Khan 10-48
Study of Hydraulic Circuit Flow Control Circuits
10.20 Flow control circuits
A1 P1 Meter-in type circuit:-

F In meter-in type of circuit we control
co ntrol flow of oil
entering
entering on actuator.
Q = Pump
Pump output (LPM)
Q1 Q1 = Fluid volume (supplied to actuato
act uator)r)
Q2 = Fluid
Fluid volume returning to tank (through
(thro ugh relief
valve)
Pump pressure (kg/c2)
P = Pump
P1 = Back-pressure
P
in actuator due to resistance
1
A = Area of cylinder (c m2)
cylinder (cm
Q2
Q
Loss of
o f energy in Meter
Meter-in-type
-in-type will be
be
M
PxQ2 _ (P-P1)xQ1
Le = (Kw)
612 612
Figure No 10.20.1
P A1 A2 P2
Meter out type circuit:-

Q
In meter-out type of circuit
circuit we control
co ntrol flow
flow of
o f oil
1
exhasting
exhasting (comig -out) from actuator.
Q2 = Q-Q1
(PxA)-F
P2 =
A2
P For same working presure

presur e and same setting of fflow
low
Q2
control
contr ol valves, the energy loss is same in meter-
meter-inin
M Q and meter-out circuit.
PxQ2 _ (P-P2)xQ1
Le = (Kw)
612 612
Figure No 10.20.2
A1
Bleed-off type circuit:-
F
In bleed-off circuit
circuit by by-pass extra oil to tank.
Q2
Q1
F
P=
A1
PxQ2
Loss of energy = Le = (Kw)
612
In bleed-off type circuit the loss of
o f energy is less
less
than meter-in or meter-out type
t ype of circuit.
circuit.
P
Q Many time
time different
different speed of actuator
actuat or required
re quired
M
using single pump. In such situation foll
fo llowing
owing
circuits are used dependin
dep ending
g on
o n requirement
Figure No 10.20.3

Khan 10-49
4) Two
Two speed circuit:-
circuit: -
In this circuit we have option of having full
A1 TWO SPEED CIRCUIT speed, which we achieve by by-passing
by-passing flow
F control
contro l valve.
valve. Or we can have controlled speed
Direction
by using
using flow
flow control
control valve.
valve. Directi
Direction
on control
c o n t r o l valve No.2 we use forfo r by-passing or blocking
valve 2
the flow
Q
M
Figure No 10.20.4
TWO CONTROL SPEED
FV1
DIRECTION
CONTROL
FV2 VALVE 2
5) Two
Two control speed:-
speed :-
In previous circuit we had one full speed and
second controll
contro lled
ed speed. But if we want to
P have two controlled speed then followng
followng cir-
cuit is used.
Q
M In neutral position
po sition of direction control valve
No.2. WeWe have speed as per setting
setting of flow
flow
control
contr ol valve number
number - FV1 .And when direc-
Figure No 10.20.5 tion control
cont rol valve
valve No.2 is energised
energised then we
have speed as per combined
combined setting ofo f FV1 &
FV2.

Khan 10-50
Functioning of two speed circuit (In this circuit

circuit both
bot h the speed could
c ould be adjusted).
A DCV in
energies
high speed
condition
Flow
Control
hence oil flow
through flow
FV2 B
control Valve
Valve isolatede
because of
colenoid valve FV1
in de-energised
conditions.
M P M
P
Figure No 10.20.2
Forward stroke.
Figure No 10.20.1
Figure No. Forward stroke (First slow speed)
C D
P M
P M
Figure No 10.20.4
Figure No 10.20.3
Return stroke.
Status of Pressure in Neutral Position
after forward stroke
In this circuit we have used meter-in
type flow-c
flow-contro
ontroll valves.
valves. To
To have two speed
spe ed
of actuator we have used one more flow
control
cont rol valve along with a solenoid valve in
parallel
parallel with first
first flow
flow control valve.
valve. Same
arrangement can be used for meter-out
meter-o ut as well
as Bleed-off circuit.

Khan 10-51
6) Three speed circuit:-

In this circuit first speed is full speed without
w ithout any control;
contr ol; second speed
sp eed is as per flow control
contr ol valve
FV1. and third
t hird speed is as per combined setting of FV1 & FV2. This manupulation we are able to
do by using special valve.
valve. (Model
(Mod el No, UCF2-04) made by M/s. Yuken Yuken India Ltd.
• In first position we by-pass FV1 & FV2. Hence get rapid

ra pid speed (full speed)
• In position 2 we by-pass FV2. Hence get medium speed as per setting of FV1 .
• In 3 rd
rd posi
positi
tion
on,, we
we get
get spe
speed
ed as per
per combi
ombine
ned
d set
setti
tin
ng of
of FV1 & FV2.
FV1
1 2 3
FV2
Q
M
• Three
Three speed also
also could
could be achieved
achieved by
by using
using fol
followi
lowing
ng circui
circuitt diagram
diagram..
A1
F
S3
• When S3 & S4 areare in

in sw
switch
tch of
off
condition
condition , we get speed as per FV1.
S4
• When
When S3 ener
energi
gise
sed,
d, we
we get
get spee
speed d as
as per
per
FV2.
FV 1 • When
When S4 enenergi
ergise
sed
d , we get
get spee
speedd as per
per
FV3.
FV 2
Q
FV 3 M

Khan 10-52
SLOW STS TART AND STOP

STO P, AND FAST MOVEMENT
MOVEM ENT CIRCUIT
CIRCUI T
To have slow start and stop and fast movement of actuator, we use folllowing circuit
diagram.
FV1 FV 2 FV 3 FV 4
S1 S2 S3 S4
S1 ON - Slow start (Flows as per FV1.)

S3 ON - Full speed (Flows as per FV1.+ FV3.)
S3 O FF - Slow stop (Flows as per FV1.)
S1 O FF - Stop
S2 ON - Slow retraction (Flows as per FV2.)
S4 ON - Fast retraction (Flows as per FV2.+ FV4.)
S4 OFF
OF F - Slow completion of retraction
tion (Flows
ows as per FV2.)
S2 O FF - Completion of retraction (Stop)

Khan 10-53
8) Continuous speed
speed control (Autometic speedspeed control):-
control):-
To have continuous
continuous speed control
co ntrol as per the demand of process, we have to use proportional
pro portional
electro-hydraulic flow control valve as per following circuit.

Khan 10-54
Study of Hydraulic Circuit Synchronisation Circuit
10.21 SYNCHRONISATION
SYNCHRONISATION CIRCUIT
By using four flow control valve we can synchronize speed of two-cylinder. But this is not a
foolproof system.
system. Error
Err or may occur and may accumulate
accumulate with every stroke. Hence error after every
stroke must be corrected.
corrected .
One of the method of co rrecting
rrecting error is to provide
pro vide lim
limit
it switches for both forward and return
stroke of both the
t he cylinder
cylinder (Total four limit
limit switches). And when both thet he limit
limit switches at one
o ne end
are actuated
actua ted then only cylinder
cylinder will
will take the
t he next stroke.
strok e. Hence on each stroke
st roke the
t he error difference
in stroke gets corrected.
co rrected. Synchronization
Synchronization could be achieved more accurately by using pressure
and temperature compensated
co mpensated flow
flow control
cont rol valve.
1. Synchronisation by using pressure and temperature

temperature compensated flow control valve
valve
Figure No 10.21.1
By using
using pressure and
a nd temperature
temperat ure compensated
co mpensated flow
flow control
co ntrol valve we can achieve
synchronisation in stroke distance
dista nce up to 95%,
95 %, but stil
st illl 5% variation may
may exist. To avoid cumulation
cumulation
of error in stroke,
stroke , at the end of each stroke error should be corrected.

Khan 10-55
2. Synchronisation by using more number of pumps -
If each cylinder is provided with individual pump with perfectly same flow, and individual
direction control
cont rol valve, then synchronisation in stroke
str oke could
cou ld be more
more accurat
a ccurately
ely achieved. But if
load on
o n individual
individual cylinder
cylinder are
ar e different
different,, the pump discharge will again vary,
vary, resulting
re sulting in variation in
stroke. In
I n this case also the error should be corrected at end of stroke.
Providin
Pro vidingg individual
individual pump for individual
individual cylinder
cylinder is very costly
co stly option. Hence Tedium gear
pumps
pumps type
type flow
flow divi
dividers
ders are used
used for synch
synchroni
ronisati
sation.
on. In this
this type
type of flow
flow devid
devider
er numb
numberer of smal
smalll
gear pumps ofo f equal discharge are assembl
asse mbleded with single spiddle or shaft. Their suction
su ction is also
common. Hence when they rotate,
rot ate, they
t hey supply equal amount of o f oil from all the pumps, which are
supplied to each actuator.
Visit
Visit the website __www.vivolo.co
__www.vivolo.com_
m_ who is manufacture
manufacturerr of such valve, to understand
underst and
them throughly.
throughly. (Ref. page no. 36-49)
These valves also give good accuracy. But as load on individual cylinder various, variation
in stroke is bound to happen. Hence correction of error
erro r at the
t he end of stroke is unavoidable.
unavoidable.
Nu mber
mb er o f smal
sm alll g ea r
pum
p um ps w it h c o mmo n
sucntion and individual
discharge for equally
dividiing main pump
discharge.(These pumps
are not connected to electric
motor. But only seves as
flow divider. they also could
be considered as hydraul
hydraulicic
gear motor)
Pump coupled to motor for

supplying
supplying oil
oil under pressure
to system.
M
Figure No 10.21.2

Khan 10-56
Synchronisation circuits for two cylinders.

Synchronisation of o f two cylinders is possible by using
using flow control
cont rol valve and tedium pump as
discussed earlier
ear lier.. Few special circuits are also possibl
po ssiblee to achieve synchronisation; some of them
are as follows.
Diamond circuit: - In this circuit

circuit two
t wo flow control
contro l valves
valves are used to
t o control
co ntrol speed of two cylinders
cylinders
in both directions. But forward and reverse speed could not be adjusted and selected separately.
separately.
Also during up stroke
stro ke the control
contr ol is meter-in and during down stroke, it is meter-o
meter-out.
ut.
To increase accuracy, one flow

flow control
co ntrol valve could be replaced with proport
pro portional
ional electro-hydraulic
flow control
contro l valve.
valve. This valve senses the variation and
a nd adjusts the
t he flow
flow to
t o achieve
ac hieve high
high accuracy
accurac y.
Doamond Circuit
Figure No 10.21.3

Khan 10-57
Pully Steel plate
Moveable element Sensor of servo

Valve
Servo Valve For

Synchronisation
M P
Synchronisation by serro -valve

Figure No 10.21.4

Khan 10-58
Study of Hydraulic Circuit Circuit Diagram of Drill
10.22 Circuit Diagram of Drill

Pump:-
A variable
variable discharge pump is used so that as load increases, speed decreases and when dr dril
ills
ls get
jamm
jammeded due to any reason it stops rotating.
rotating. Reduced
Reduced or no discha
dischargerge from variabl
variablee displ
displacem
acement ent
pump
pump at high
high pressure
pressure safe
safe guard agains
againstt oil heatin
heating.
g.
Direction control valve :-
Advantage of using three positions
p ositions all port block valves is that at neutral position cylinder cylinder remains
locked, and it does not drain-out system pressure.
Flow control valve : -
By using
using flow control
contro l valve
valve we control
contro l spindle
spindle approach
appro ach and return
retur n speed.
Four-way-two
Four-way-two position
po sition direction cont controlrol valve :-
Because of two positions, cylinder will either clamp or un-clamp. Circuit is designed in such a way
that when
whe n solenoid valve un-energised
un-energ ised it remains
remains in clamp
clamp position. These safeguards
sa feguards accidental
ac cidental
released of job.
Check valves safeguards variable displacem displacement ent pump
pu mp against sudden over loading loading and accesses
pressure
pressure generated
generated in cyli
cylinde
nders.rs.
J-type direction contcontrol valve  is used for drill head feed cylinder, so that pressure
rol valve pr essure should
shou ld not
be locked in pipe lineline of cylinder
cylinder.. Locked
Locked pressure may actuate the pilot pilot operated check valve valve
which holds spindle in lifted
lifted condition.
cond ition.
Counter balance valve  develops a back pressure, pre ssure, because of o f which
which drill head does not no t over
travel due to weight of spindle.
spindle. Because of counter balance balance valve,
valve, flow control
contro l valve
valve also works
wor ks
accurately.
Pilot operated check valve 
Drill Head feed Cylinder
locks drill head feeding
feeding cylinder
cylinder Lift Cylinder Clamp Cylinder
in position, so that
t hat when drill
dr illing
ing
Unclamp clamp 8
stops, spindle remain stationery Up 2
and do not slides down due to Down

10
own weight. 3
4
Reducing valve  is used to
reduce pressure supplied to up- 7
down cylinder withou
withoutt reducing 2
system pressure.
Meter-out type flow controlcon trol
valve  is used to control 6
spindle
spindle speed.Meter-out type
9
valve reduces fluctuation in
speed much better than meter-
5
in type circuit,with change in 5
cutting load.
Figure No 10.22.1

Khan 10-59
Study of Hydraulic Circuit Honning
10.23 Honning
What is honning?
Honing is simil
similar
ar to internal grinding,
grinding, but in this process instead
instea d of grinding wheel grinding stone
sticks are used and
a nd grinding
grinding stone
st one sticks are rotated
rotat ed as well as reciprocated inside
inside an cylindrical
cylindrical
object to remove material of object as per requirement. In honing, ovalityovality as well as taper of inside
inside
diameter
diameter is corrected.
correct ed. As per the size and grade of honinghoning stone
sto ne stick used for honing
honing we get
surface finish
finish better than
t han grinding process. Honing process
proc ess is generally used iin
n manufacturing of
hydraulic cylinder
cylinder or cylinder of aut
automo
omobil
bilee engine.
High flow high pressure pump :- To reciprocate honing head at required high speed high flow flow
pump
pump is used as per requireme
requirement. nt.
Relief valve  regulates pressure of reciprocating cylinder.
Flow control valve controls
contr ols the speed of reciprocat ing cylin
cylinder.
der.
Direction control valve  controls
contr ols the direction of reciprocating
recipro cating cylinder.
cylinder.
This simple counter balance valve  offers some back pressure pressur e when cylinder
cylinder descends down,
do wn,
HONNING
11 14
10
13
9
12
1
7
2 P M P
Figure No 10.23.1
because
because of this
this speed
speed of cyli
cylinder
nder remai
remains
ns under
under control as per flow control
control valve
valve setting.
setting.
Reciprocating cylinder : - In honing machine
machine up and
a nd down speed of honing head should be
same, hence either cylinder in mode double ended. Or differential cylinder is used along with
regenerative
regenerat ive circuit.
circuit.
Pump with low discharge is used for hydraulic motor o f honing head, as revolving speed of
honing head is between
betwe en 10-70
10-7 0 rpm only,
only, and clampi
c lamping
ng cylinder is
is operat
ope rated
ed only at the beginni
be ginning
ng
operation. Relief valve  controls
and at the of operation. contro ls working pressure of pump No. 7

Khan 10-60
Study of Hydraulic Circuit Honning
Direction control valve  and 12 are used in series because because of two reasons.
a) Flow
Flow is small hence heat
heating
ing will
will be minimum.
minimum.
b) Clam
Clampiping
ng cyli
cylinder
nderss are rarely
rarely used, hence
hence it does not interf
interfere
ere func
function
tionin
ing
g of hydraul
hydrauliic motor.
motor.
If we use all port block valve
valve in such situation, then one more valve
valve we have to add to unload pump
when both hydraulic motor and clampingclamping cylinder
cylinder are not in use. Hence by using two direction
direct ion
control
cont rol valve in
in series we save one valve.
va lve.
Flow control valve , controls
cont rols and varies the speed of hydraulic
hydraulic moto
motorr attached
attac hed to honing head.
Hydraulic Motor 11 :- rotates
rot ates the honing head. By using
using hydraulic motor
moto r in place of general
geared electric moto
motor,r, we have full and easy control over speed and torque torq ue of honing
honing head.
Pilot operated check valve 13 locks the t he clamping
clamping cylinder
cylinder under pressure. Clamping cylinder 14
holds the job firmly,
firmly, as in honing job is subjected to rotary
rot ary torque
to rque as well
we ll as up and
a nd down pulli
pu lling
ng
and pushing force.
In this hydraulic
hydraulic circuit we have used meter in type flow flow contro
c ontroll valve.
valve. Bleed of
o f type is
is also used.
use d.
In bleed-off power loss is comparatively less.

Khan 10-61
Study of Hydraulic Circuit
CIRCUIT DIAGRAM OF
SURFACE GRINDING MACHINE

Table slide cyl.
clamp cyl .
Ø 100 x Ø 75 x 5000mt
Lubrication
Lub.Return
20 kg/cm 20kg/cm 0.5 2kg/cm
M
7/min 95/min
7.5kw
500
Figure No 10.23.2

Khan 10-62

Volume5 Study of Hydraulic Circuits

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Volume5 Study of Hydraulic Circuits

Загружено:

Авторское право:

Доступные форматы

Q. S.

10.1 What is circuit?

10. Introduction to Hydraulic Circuit

“Design and Manufacturing of Hydrauli

10.2 Classification of Hydraulic Circuit

Hydraulic power system or hydraulic circuit

An open-loop hydraulic circuit do have all the basic

Constant flow circuit and demand flow circuit:-

These two terms are also used for

10.3 Selection of different circuit for same function

“Design and Manufacturing of Hydrauli

10.4 Selection of working

HYDRAULIC CIRCUIT DIAGRAM

• We will select three pressure 35 0 kg/cm2 and find the capacity

“Design and Manufacturing of Hydrauli

• CETOP is an international standard for standardising

PVR- Rs 2RCE-7- Rs Polyhydron 2R CE- 7- CC Rs

4. Direction Control Yuken DMG-o6 Rs Polyhydron 4DL-10- Rs Polyhydron 4DC-1D-G- Rs

“Design and Manufacturing of Hydrauli

3. Relife Valve 30 - 70 Kg/c 2

Above data based on o n general study and old trend of

“Design and Manufacturing of Hydrauli

10.5 Pressure Drop in Hydraulic System

“Design and Manufacturing of Hydrauli

10.6 Calculation of Heat Generation In Hydraulic System

Heat generation due to loss of efficiency:-

Heat generation due to t o pressure drop:-

“Design and Manufacturing of Hydrauli

 Pressure drop in hydraulic cylin

Sr.No. Components Make Make Detail and Pressure Drop

“Design and Manufacturing of Hydrauli

1 Kw/hr = 860 Kcal

For removing 2656 kcal/ hr heat we need =

“Design and Manufacturing of Hydrauli

Operation of Deep drawing Press: -

“Design and Manufacturing of Hydrauli

Sequence of Operation Chart

Main Cylinder ON ON OFF OFF OF

Note : S1, S2,S3, S4, S5

Note: - A simpl

“Design and Manufacturing of Hydrauli

r Blank holding

“Design and Manufacturing of Hydrauli

10.8 Circuit Diagram For Modular Type

Direction controll valve (4) 2

Pilot operated check valve (6)

Flow control valve (5)

Flow control Relief valve (3)

P P Manifold or Flow control

“Design and Manufacturing of Hydrauli

Some of the logic and feature of making

Second Valve Bank First Valve Bank

Flow controll Flow controll

Pilot opareted Pilot opareted

Relief valve Relief valve

Figure No. 35.24

“Design and Manufacturing of Hydrauli

10.9 Use of filter in Hydraulic Circuit:-

1) Circuit with suction stainer:-

“Design and Manufacturing of Hydrauli

10.10 What is Pumping Unit and Powerpack Unit?

Motor and Pump assembly

Power pack unit