Hydraulic Circuit Design and

Analysis
Hydraulic Circuit: A hydraulic circuit is
an arrangement of components like
pumps, actuators, control valves and
conductors so as to perform some useful
task
Three important considerations when
designing or analyzing a hydraulic circuit;
1. Safety of operation
2. Performance of desired function
3. Efficiency of operation
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 Hydraulic circuits are developed

using graphical symbols for all
components
These symbols are as per the
American National Standards
Institute (ANSI)
Symbols:
refer figure 9.1 in the text book.

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 Control of a single acting hydraulic

cylinder:
A two position three way manually
actuated spring offset DCV is used to
control a single acting hydraulic cylinder

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 When spool of the DCV is positioned in the

left envelope, flow from the pump goes to
the cylinder
Piston extension takes place
When piston has extended the maximum
then pressure inside the cylinder starts
mounting
This causes pump flow to get redirected to
the tank via pressure relief valve
At this time manual lever is left, offset
spring positions the valve in the right
envelope
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 In the spring offset position of the

spool in DCV rod side spring starts
retraction of the piston and full pump
flow goes to the tank via pressure
relief valve
When piston retraction takes place
hydraulic fluid flows from the cylinder
to the tank

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 Control of a double acting hydraulic

cylinder:

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 A four way three position manually actuated

spring centered valve is used here as DCV
In spring centered position the cylinder is
hydraulically locked
The pump is discharging to the tank directly
Now DCV is put in the flow path configuration
of the left envelope using manual lever
This causes the flow from the pump to the
cylinder and piston extends against F load
The hydraulic fluid from the other side of the
piston drains to tank via port B

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 What will happen if this hydraulic oil

from the rod side of the cylinder was
not allowed to drain???
Now lever is left and the valve is again
spring centered
When DCV is put in the flow path
shown by right envelope then piston
starts retracting
Pump flow takes place from P to B and
oil in the blank end flows to the tank
via A and T
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 At the end of the stroke pump flow

goes trough the relief valve to the tank
What if the valve is centered after the
stroke??
REGENERATIVE CIRCUIT
In the figure a regenerative circuit is shown
It is used to increase the extension speed
of the piston
When the DCV is put in the flow
configuration shown by the left envelope
using a manual lever then ;
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 Flow takes place from P to A

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 As B is blocked so the fluid on rod side

comes via by-pass line
This flow gets added to the pump flow
Because of this extra flow piston
extends at a higher rate as compared
to normal double acting piston
In the spring centered position
represented by mid envelope no flow
takes place through the DCV
Pump flow goes to the tank via
pressure relief valve
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 When DCV is put in the flow path

configuration represented by the left
envelope then;
Piston retraction takes place
Fluid from the blank end flows
through the DCV and to the tank
Fluid from the pump goes to the rod
end via by-pass line (as B is blocked)

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 Total flow and other equations,

QT QP QR
we _ also _ know _ that ;
QT AP .vPext
and ,
QR ( AP Ar ).vPext
so,
QP AP .vPext ( AP Ar ).vPext
this _ gives;
vPext

QP

Ar
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 This means a smaller rod area will

give more extension speed for the
cylinder
Ratio of extending
and retracting
QP
vP
speeds;
A A
r et

so,
vPext
vPr et

QP

QP

Ar

( AP Ar )

AP

1
Ar
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 Load carrying capacity;

Load carrying capacity of a regenerative
circuit is less than that of a normal
double acting cylinder
WHY???
Pressure on both the sides of the piston
are same in regenerative circuit
Although this is not the case for a normal
double acting cylinder
So for a normal double acting cylinder
force during extension is P.AP and for a
regenerative circuit it is P.Ar
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 Drilling machine application

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 Operation;
In spring centered position rapid spindle
(piston) extension takes place
Left envelope mode gives slow feed when
drill enters the material
Right envelope makes retraction of the
piston
Why spring centered position gives rapid
extension of the cylinder?
Answer is regeneration
Oil from the rod end regenerates with the
pump flow going to the blank end
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 Pump unloading circuit;

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 Operation;
In spring centered position DCV is
hydraulically locked
Pump flow goes to check valve and provides
pilot pressure
Pilot opens the exhaust port of the
unloading valve and pump is unloaded
When DCV is positioned in the flow path
configuration represented by the left
envelope, piston extension starts
At the end of the extension stroke, the pilot
valve provides high pressure to the
unloading valve
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 Operation;
This opens the unloading valve and
pump is unloaded at the end of the
extension stroke
When DCV is put in the flow
configuration represented by the right
envelope piston retracts
At the end of the retraction stroke check
valve plays the same role again and
unloads the pump

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 Double pump hydraulic system;

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 Operation;
In the application of a punching press
high flow is required at low pressure
until the press gets in contact with the
material (as movement is more)
After the press gets in contact with the
material less movement is there
This requires low flow rate at high
pressure

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CONGRATULATIONS TO ALL!!!

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WHAT HAS BROUGHT CRICKET WORLD

CUP TO INDIA???
THE RIGHT GOAL SETTING
THE RGHT ROADMAP
THE RIGHT PLANNING
THE RIGHT EXECUTION
AND

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SOME HIGHLY DISCIPLINED,

STIMULATING, MOTIVATING
AND MEMORABLE INDIVIDUAL
PERFORMANCES!!!

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WISH YOU ALL A SIMILAR

SUCCESS IN YOUR ACADEMIC AND
PROFESSIONAL LIFE!!!

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 Pressure intensifier circuit

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 Operation;
Left envelope flow path configuration
causes retraction of the piston
Flow goes from the pump to the rod end
via A
From the pump line pilot pressure is
provided to the pilot operated check valve
This causes the check valve to open
So fluid from the blank end drains through
the check valve and B
In the middle envelope flow path
configuration, DCV is hydraulically locked
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 Operation;
Pump flow goes to the tank via pressure
reducing valve
In right envelope flow path configuration, pump
fluid goes to the blank side via B and sequence
valve
Piston extension takes place
In the beginning pressure in the cylinder is less
Then the pressure increases inside the cylinder
This flow can not bypass through check valve
It goes through the sequence valve and a high
pressure is maintained
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 Counter-balance Valve Circuit

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 Operation;
Using flow path configurations of left
envelope and right envelope the two
way action of the piston is achieved
Counter-balance effect is provided by
the centered envelope
Taking a look at the centered envelope
suggest that,
When pressure on top side increases, it will
push the piston downwards
This will increase pressure inside the
cylinder below the piston
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 Operation;
Check valve will be closed at this high
pressure value
Flow will take place through the sequence
valve
In the centered envelope top side and
bottom side of the piston are connected
mutually and to the drain tank also
So pressure increased at the top side is
counterbalanced

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 Hydraulic cylinder sequencing circuit;

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 Operation;
When the DCV is put in the left envelope mode,
left cylinder starts extending
The flow to the left cylinder blank side takes
place through A
The flow from the rod side of the left cylinder
takes place through B and check valve
When left cylinder has extended completely,
pressure at the inlet of the sequence valve of
the right cylinder goes above the preset value of
the valve
Check valve remains closed and blank side of
the right cylinder gets fluid through the
sequence valve
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 Operation;
Fluid from the rod side of the right cylinder
drains out through port B
When DCV is put in the right envelope mode,
retraction of the right cylinder takes place
first
Fluid goes to the rod side of the right cylinder
through port B directly
Fluid from the blank side drains through the
check valve and port A
When right cylinder has retracted completely
pressure at the blank side goes very high this
increases pressure at the rod side also
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 Operation;
This high pressure causes the sequence
valve connected to the left cylinder to
open
Thus fluid goes to the rod side of the left
cylinder and retraction of the left
cylinder starts
Fluid from the blank side of the left
cylinder is drained through port A
directly
What about centered position
envelope???
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 Automatic Cylinder Reciprocating

System;

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 Locked cylinder using pilot check

valve

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 Cylinders Synchronization-parallel
arrangement

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 Cylinders Synchronization-series
arrangement

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 Equations

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 Fail safe circuit- Protection against

unwanted cylinder extension

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 Fail safe circuit with overload

protection

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 Two hand safety circuit

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 Speed Control of a hydraulic cylinder;

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 Analysis of speed control;

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