Hydraulic Circuits

by
Prof. Reda I. Afify
 Hydraulic Circuits
A hydraulic circuit is a group of components such as pumps,
actuators, control valves, and conductors so arranged that they will
perform a useful task.

Important considerations must be taken into account:

• Safety of machine.
• Performance of given operation with minimum losses.
• Cost of the component used in the circuit.
Control a single-acting hydraulic cylinder
Control a double-acting hydraulic cylinder
Position 1: The cylinder is
extended against its load
force, Fload as oil flows from
P to A and B to T

Position 2: The cylinder

retracts as oil flows from P
to B and A to T

Center position:
A 4/3 DCV (tandem)
Control a double-acting hydraulic cylinder

➢ At the ends of the stroke, there is

no system demand for oil. Thus,
the pump flow goes through the
relief valve at its pressure-level
setting unless the four-way valve
is deactivated. In any event, the
system is protected from any
cylinder overloads.

➢ The check valve prevents the

load (if it becomes excessive)
from retracting the cylinder while
it is being extended using the left
envelope flow path configuration.
Regenerative Circuit
A Regenerative circuit is a system that is used to increase the speed
of extension stroke of the double acting single rod hydraulic
cylinder. The output is connected to the input in the directional control
value. By this concept, increase in velocity of the piston and decrease
the cycle time.
Regenerative Circuit where
Ap = A = piston area
a = rod area
During extension Ar = A-a = rod-side area
The actuator velocity will be: F = force

Q+q q q
Vext = = =
A Ar A − a

Q(A - a) + qA - qa = qA
Q(A - a) = qa
q
Q=  a = Vext  a
( A − a)
Q
Vext =
a
From Pascal's low
PA = P( A − a) + Fext
Fext = Pa
Regenerative Circuit

During retraction

Q Q
Vret = =
Ar A − a
and the force:

Fret = P x Ar = P x (A - a)

where
Ap = A = piston area
a = rod area
Ar = A-a = rod-side area
F = force
Regenerative Circuit
Ratio of extending and retracting speeds

Q Q
Vret = =
Ar A − a

Vext A r A p − a A p
= = = −1
Vret a a a

We can that when the piston area equals two times the rod
area, the extension and retraction are equal.
Regenerative Circuit
Drilling Machine Application
The application is for a drilling machine, where the following
operations take place:
• The spring-centered position gives rapid spindle advance
(extension).

• The left envelope mode

gives slow feed (extension)
when the drill starts to cut
into the work-piece.

• The right envelope mode

retracts the piston.
Pump-Unloading Circuit

The pump unload at end of the

extending and retraction strokes
because the check valve keeps the
high-pressure oil. Due to high-
pressure oil in the pilot line of the
unloading valve, it opens and
unloads the pump pressure to the
tank.
Double-pump hydraulic system
Pump A has low flow rate and high pressure, and pump B has high
flow rate and low pressure.
For rapid motion during no load "high velocity"
Flow rate to the piston, Qpiston

Qpiston = Q A + QB

Pressure of the piston, Ppiston

Ppiston = PB
Double-pump hydraulic system
For low motion during load "low velocity"
Flow rate to the piston, Qpiston

Qpiston = Q A

Pressure of the piston, Ppiston

Ppiston = PA

• Unloaded valve open the pump B to

tank with zero pressure.
• Check valve protect pump B from high
pressure of pump A during work stroke.
• Pressure relief valve protect high
pressure pump A from over pressure.
Counter-Balance Valve Application
Mostly counter valves are used to
prevent the weight from falling
uncontrollably, these valves are
used to maintain backpressure so
that it can prevent a load from
falling.

Valve Operation (Lowering)

Due to this back pressure in line A,
the actuator piston must force
down when the load is being
lowered. This causes the pressure
in line A to increase, which raises
the spring-opposed spool, thus
providing a flow path to discharge
the exhaust flow from line A to the
DCV and then to the tank.
Hydraulic Cylinder Sequence Circuit
During extending, the cylinder A could extends and clamp a work-piece via
a power vise jaw. Then the cylinder B extends to drive spindle to drill a hole
in the work-piece.
Hydraulic Cylinder Sequence Circuit
During retracted, the cylinder B then retracts the drill spindle, and then
the cylinder A retracts to release the work-piece for removal.

Center position of DCV:

holding
Cylinders Synchronize Circuit
Cylinders Connected in Parallel
When the two cylinders are identical, the loads on the cylinders are
identical, and then extension and retraction are synchronized. If the
loads are not identical, the cylinder with smaller load extends first.
Thus, the two cylinders are not synchronized.

Cylinders Hooked in Parallel will not Operate in Synchronization

Cylinders Synchronize Circuit
Cylinders Connected in Series
Cylinders Connected in Series
Qout,cylinder1 = Qin,cylinder 2

Qout,cylinder1 = A r1Vex1 = ( A p1 − a1)Vex1

Qout,cylinder1 = A p2 Vex 2
( A p1 − a1)Vex1 = A p2 Vex 2

If two cylinders to be synchronized,

Vex1 = Vex 2
Therefore,

A p1 − a1 = A p2
Cylinders Connected in Series
P1A p1 − P2 ( A p1 − a1) = F1

P2 A p2 − P3 ( A p2 − a 2 ) = F2

A p2 = A p1 - a1

P3 = 0
P1A p1 = F1 + F2

Power of the pump = P1Q

Speed Control of hydraulic Cylinders
Meter-in flow control circuit represents
the controlling of fluid flow just before fluid
enters to the actuator with the help of flow
control valve.
The Operation is as follows during
extension stroke:
• When the DCV valve is actuated, oil
flows through the flow control valve to
extend the cylinder.
• When the DCV is de-actuated into its
spring-offset mode, the cylinder retracts
as oil flows from the cylinder to the oil
tank through the check valve as well as
the flow control valve.
Analysis Extending Speed Control
Qcyl = Qpump - QPRV = QFCV
QFCV = Cv [p/SG] = Cv [(P1 - P2 )/SG]

P2 A piston = Fload or
P2 = Fload /Apiston

Vcyl = Qcyl/ Apiston

= QFCV / Apiston

Cv
Vcyl = [(PPRV - Fload /A piston )/SG]
A piston
where
∆p = pressure drop across FCV.
Cv = capacity coefficient of FCV,
SG = specific gravity of oil.
p1 = pPRV = PRV setting.
Meter-Out Flow Control Valve Systems
With meter-out speed control, the
quantity of oil leaving the cylinder is
controlled. When the cylinder is
extending, the oil from the rod-end is
metered which a smaller quantity than
that is flowing into the full-bore end.

A meter-out flow control system is one

in which the FCV is placed in the outlet
line of the hydraulic cylinder. Thus, a
meter-out flow control system controls
the oil flow rate out of the cylinder.
 Sheet (Hydraulic Circuits)
When analyzing or designing a hydraulic circuit, what three important
considerations must be considered.
Draw the circuit of a simple hydraulic system, including a pump,
directional control valves, hydraulic cylinder, relief valve, and pressure
gauge. State the function of the individual elements and discuss in
detail the power transmission and transformation in the hydraulic
power systems.
What is the purpose of a regenerative circuit. Draw hydraulic
regenerative circuit
What is the purpose of an unloading valve. Draw hydraulic circuit of
double-pump, one of large flow with low pressure and another small
flow with high pressure.
Draw hydraulic circuit contain two cylinders hooked in series operate
in synchronization.
 Sheet (Hydraulic Circuits)
Draw hydraulic circuit contain two cylinders hooked in parallel.
Draw hydraulic circuit contain meter-in speed control of hydraulic
cylinder during extending stroke using flow control valve.
Draw hydraulic circuit contain meter-out speed control of hydraulic
cylinder during extending stroke using flow control valve.
The End

Thank You

Prof. Reda I. Afify