Hydraulic Circuit Design

1
MEL334: Low Cost Automation 1

Hydraulic Circuit
Design & Analysis
Dr. Sunil J ha
Design Considerations
Safety of Operation
Pressure and Temperature ratings
Interlocks for sequential operations
Emergency shutdown features
Power failure locks
Operation speed
Environment conditions
2
Meet functional requirements
Meet required performance specification
Life expectancy same as machine
Facilitate good maintenance practice
Compatibility with electrical and mechanical
components
Withstand operational hazards
Efficiency of Operation
Keep system Simple, Safe and Functional
Access to parts need repair or adjustment
Design to keep min operational cost
Design to prevent and remove contamination.
3
Linear Circuits
Simple reciprocating circuit
Reservoir
Strainer
Pump
Flexible coupling
Electric Motor
Connectors
Relief valve
DCV 4 way
Hyd. Cylinder
Circuit Design Approach
What are the specifications of the job?
Force requirement 8 kN
Length of work stroke 15 cm
Speed of piston and rod assembly 0.5 sec
What Size of Cylinder is needed?
Force known. Cylinder Area & Operating
Pressure must be selected. F = PA F = PA
Standard bore and rod size cylinders
4
Cylinder Selection Reasoning
Large Diameter Cylinder
Operates at Low Pressure
Requires Bigger pump for speed
Small Diameter Cylinder
Operates at High Pressure
Smaller pump give speed
Cylinder selected =50 mm bore
Find Pressure and then select suitable pump
What Capacity Pump is needed?
Max Cylinder Speed required
Flow rate =(Cyl Area)x(Stroke)/(time)
Pump selection
What size of Electric Motor needed?
Calculate power required to run Pump
Consider efficiency of pump
Shaft size, type and electric source
5
What Size reservoir should be used?
2.5-3.0 times the pump capacity
What size of Electric Motor needed?
Calculate power required to run Pump
Consider efficiency of pump
Shaft size, type and electric source
Size of pump inlet?
Inlet flow velocity =60-150 cm/sec
Size of Discharge tubing?
Outlet flow velocity =200 450 cm/sec
Relief valve selection
Pressure range
Valve port size
Direction Control valve
Based on function
6
Control of a Single Acting Hydraulic
Cylinder
Two Position
Three Way
Manually Actuated
Spring Offset
DCV
Control of a Double Acting
Hydraulic Cylinder
Three Position
Four Way
Manually Actuated
Spring Centered
DCV
7
Regenerative Circuit
Pressurized fluid
discharge returned
to system
Speed up
extending speed
Retraction bypass
DCV
Extend Retract
Qt
Qr
Qp
Qt =Qp +Qr
Drilling Machine Application
Spring centered
position Rapid
spindle advance
Left envelope
Slow feed
Right envelope
Retracts piston
8
PUMP Unloading circuit
Unloading valve
unloads the pump
at the ends of
extending and
retracting strokes
As well as in
spring centered
position of DCV
Double Pump Hydraulic System
Punch Press
Initial Low
Pressure high
flow rate req.
When punching
operation begins,
increased
pressure opens
unloading valve
to unload low
pressure pump.
Unload
Valve
Relief
Valve
9
Counterbalance Valve
To keep vertically
mounted cylinder in
upward position while
pump is idling.
Counterbalance
valve is set to open
at slightly above the
pressure required to
hold the piston up.
Hydraulic Cylinder Sequence
Circuit
Left Env: Left Cyl
extends completely
and then Right Cyl
extend.
Right Env: Right Cyl
retracts fully and
then Left Cyl
retracts.
10
Automatic Cylinder Reciprocating
System
Two sequence
valve sensing
strokes completion
by corresponding
pressure build up.
Locked Cylinder using Pilot Check
Valves
Lock Cylinder so that
piston can not move
by external load.
11
Cylinder Synchronizing Circuit
Cylinders connected in parallel
Loads identical Moves in exact synchronization
Loads Not exactly Identical (practical situation)
Cylinders also not exactly identical (packing Friction)
Cylinders connected in Series
For two cylinder to be synchronized
Piston Area of Cyl 2 =Piston Area of Cyl 1-
Rod area
12
Pump pressure should overcome load
acting on both cylinders.
P
1
A
p1
- P
2
(A
p1
-A
r1)
= F
1
P
2
A
p2
- P
3
(A
p2
-A
r2
) = F
2
A
p2
= A
p1
-A
r1
P
3
= 0
P
1
A
p1
= F
1
+F
2
Q. For the Cylinder Synchronizing Circuit, what pump
pressure is required if the cylinder loads are 22kN
each and cylinder 1 has a piston area of 65 cm
2
?
13
Fail Safe Circuit
Designed to prevent injury to operator or
damage to equipment.
Prevent Cylinder from
accidentally falling on an
Operator in the event of:
Hydraulic line ruptures
Person inadvertently operates
manual override on Pilot
actuated DCV when pump not
operating
Fail Safe Circuit with Overload
Protection
DCV-1 controlled by Push button
valve-2.
When Overload Valve -3 is in
spring offset mode, it drains the
pilot line of valve 1.
If Cyl experience excessive
resistance, Valve-4 actuates
overload valve -3. This drains
pilot line of Valve1, causing it to
return to spring offset mode.
Nothing happen if push button 2
pressed unless overload valve
shifted manually into blocked
configuration.
14
Two hand Safety Circuit
Designed to protect
an operator from
injury.
For circuit to
function, operator
must depress both
manually actuated
valves.
Any one button
prevents operation.
Speed Control of a Hydraulic Motor
Hydraulic Motor Rotary Motion
Spring Center Position
Motor hydraulically locked
Left Envelop
Rotates Clockwise
Right Envelop
Rotates Anticlockwise
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Speed Control of a Hydraulic Motor
Hydraulic Motor Braking System
Hydraulic motor may be driving Machine having
a large inertia.
Creates Flywheel effect.
Stopping motor, acts as a pump.
Circuit is designed to provide fluid to the motor
while it is pumping.
Provisions should be made for discharge fluid
from motor to be returned to Tank.
This would stop motor without damaging.
16
Hydraulic Motor Braking System
Hydrostatic Transmission
Open Circuit Drives
Pump draws fluid from reservoir
Pump output directed to Hydraulic Motor
Discharge from Motor into reservoir
Closed Circuit Drive
Exhaust oil from the motor returned directly to
pump inlet.
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Closed Circuit One-Direction
Closed Circuit that
allows only one direction
of motor rotation.
Motor speed varied by
changing pump
displacement.
Torque capacity of motor
adjusted by pressure
setting of the relief valve.
Closed Circuit Reversible Direction

Hydraulic Circuit Design

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MEL334: Low Cost Automation 1

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