LECTURE 4: HYDRAULIC CIRCUIT DESIGN AND ANALYSIS

A Hydraulic circuit is a group of components such as pumps, actuators, and control valves so
arranged that they will perform a useful task. When analyzing or designing a hydraulic circuit, the
following three important considerations must be taken into account:

 Safety of operation
 Performance of desired function
 Efficiency of operation

It is very important for the fluid power designer to have a working knowledge of components and
how they operate in a circuit. Hydraulic circuits are developed through the use of graphical
symbols for all components. The symbols have to conform to the ANSI specification.

Control of a Single - Acting Hydraulic Cylinder :

A single-acting cylinder can exert a force in only the extending direction as fluid from the pump
enters the blank end of the cylinder ( usually left side of the piston). Single- acting cylinder do not
retract hydraulically. Retraction is accomplished by using gravity or by the inclusion of a
compression spring in the rod end.

o Force during extension stroke is , Fext = P * AP

o Velocity during extension stroke is , vP ext = QP / AP

The force and velocity during retraction stroke depends upon spring rate as single – acting cylinder
do not retract hydraulically

The Figure below shows a two- postion, three way, manually operated, spring offset directional
control valve ( DCV ) used to control the operation of a single – acting cylinder. In the spring
offset mode, full pump flow goes the tank via the pressure relief valve. The spring in the rod end
of the cylinder retracts the piston as oil from the blank end ‘A’ drains back to the rank. When the

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valve is manually actuated the pump flow goes to the cylinder blank end ‘A’ via DCV 1 position.
This extends the cylinder. At full extension, pump flow goes through the relief valve. Deactivation
of the DCV allows the cylinder to retract as the DCV shift into its spring – offset mode.

C = Single acting cylinder

P = Pump

E = Electric Motor

T = Tank

F = Filter

R = Relief Valve

D =2-position, 3 way DCV Manually operated and spring return

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Control of Double -Acting Hydraulic Cylinder :

Double –Acting cylinders can be extended and retracted hydraulically. Thus, an output force can
be applied in two directions.

The output force ( F ) and piston velocity of double acting cylinder are not the same for extension
and retraction strokes. During the extension stroke, fluid enters the blank end (A) of the cylinder
through the entire circular area of the piston (AP). However during the retraction stroke, fluid enters
the rod end through the smaller annular area between the rod and cylinder bore (AP – AR),

o AP = piston area
o AR = rod area.

Since AP = is greater than (AP – AR), the retraction velocity is greater than the extension velocity
since the pump flow rate is constant.

Similarly during the extension stroke, fluid pressure bears on the entire area of the piston (AP).
However during the retraction stroke, fluid pressure bears on the smaller annular area (AP – AR).
The difference in area accounts for the difference in output force, with the output force is greater
during extension.

Extending stroke :

Force, Fext = p * AP -------- 1

Velocity, vext = Qp / AP -----2

Retraction Stroke :

Force, Fret = p * ( AP – Ar ) --- 3

Velocity, Vret = Qp / (AP – Ar ) --- 4

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It can be seen from the above 4 equations that force during extension stroke and velocity of piston
during retraction stroke is greater for the same operating pressure and flow rate.

The power developed by a hydraulic cylinder for either the extension or retraction stroke, can be
found out by (velocity multiplied by force) or from ( flow rate multiplied by operating pressure )

Power ( kW ) = VP (m/s) * F ( kN ) = Q ( m3/s) * P ( kPa )

The Figure below shows a circuit used to control a double – acting hydraulic cylinder.

 When the four way valve is in centered configuration , the cylinder is hydraulically locked
as the ports A and B is blocked. The pump flow is unloaded back to the tank at essentially
atmospheric pressure.
 When the four way valve is actuated into the 1st position , the cylinder is extended against
its load force Fload as oil flows to the blank end of the cylinder from port P through port A
. Also, oil in the rod end of the cylinder is free to flow back to the tank via the four way
valve from port B through port T. Note that the cylinder would not extend if this oil were
not allowed to leave the rod end of the cylinder.
 When the four way valve is actuated into the 2nd position , the cylinder retracts against as
oil flows to the rod end of the cylinder from port P through port B. Oil in the blank end of
the cylinder is returned to the tank from port A to port T. At the end 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.

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 C = Double acting cylinder

P = Pump

E = Electric Motor

T = Tank

F = Filter

R = Relief Valve

D =3-position, 4 way ,Tandem center, Manually operated and

Spring Centered DCV

Problem 1.

A double acting cylinder is hooked up to reciprocate. The relief valve setting is 70 bars. The piston
area is 0.016 m2 and the rod area is 0.0045 m2. If the pump flow is 0.0013m3 / s, find the cylinder
speed and load- carrying capacity for the

a. Extending stroke

b. Retracting stroke.

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Solution:

Relief valve pressure setting, p = 70 bars = 70 * 105 N /m2

Piston area, Ap = 0.016 m2

Rod area, Ar = 0.0045 m2

Pump flow, Qp = 0.0013 m3/s

a) Extending Stroke :

Cylinder speed, Vp ext = Qp / AP = 0.0013 / 0.016 = 0.0813 m / s

Load carrying capacity, Fload = P * AP

= 70 * 105 * 0.016

= 112000 N = 112kN

b) Retracting Stroke :

Cylinder Speed, Vp Ret = Qp / (AP – Ar)

= 0.0013 / ( 0.016 - 0.0045 )

= 0.113 m / s

Load carrying capacity, Fload = p * ( AP – Ar )

= 70 * 105 * ( 0.016 - 0.0045

= 80500 N = 80.5kN

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Regenerative circuit

Operation

Figure below shows a regenerative circuit that is used to speed up the extending speed of a
double-acting hydraulic cylinder. Here the pipelines to both ends of the hydraulic cylinder are
connected to pump, one end (A) through the 2 / 3 way DCV and the other end (B) directly. The
operation of the cylinder during the retraction stroke is the same as that of a regular double-acting
cylinder. Fluid flows through the DCV zero position from the actuator A side during retraction. In
this position, fluid from the pump directly enters the rod end of the cylinder (direct connection).
Fluid in the blank end drains back to the tank through the DCV as the cylinder retracts.

When the DCV is shifted to 1 position due to manual actuation, the cylinder extends. The speed
of extension is greater than that for a regular double-acting cylinder because flow from the
rod end (QR) regenerates with the pump flow (QP) to provide a total flow rate (QT), which is greater
than the pump flow rate to the A side of the cylinder. (Area of blank end is more than rod end,
thereby blank end provide least resistance)

C = Double acting cylinder

P = Pump

E = Electric Motor

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 T = Tank

F = Filter

R = Relief Valve

D =2-position, 3 way , Manually operated and Spring return DCV

Cylinder Extending Speed

The total flow rate entering the blank end (A) of the cylinder equals the pump flow rate plus the
regenerative flow rate coming from the rod end of the cylinder:

QT = QP + QR

QP = QT - QR ---(1)

We know that the total flow rate equals the piston area multiplied by the extending speed of the
piston (Vpext). Similarly, the regenerative flow rate equals the difference of the piston and rod areas
(Ap - Ar) multiplied by the extending speed of the piston. Substituting these two relationships into
the eq (1) yields

QP = ApVpext – (Ap – Ar)Vpext

but QP = ArVpext

Hence the extending speed of the piston, Vpext = QP / Ar --- (2)

Ratio of Extending and Retracting Speeds

Let’s determine under what condition the extending and retracting speeds are equal. We know that
the retracting speed (Vpret) equals the pump flow divided by the difference of the piston and rod
areas:

Dividing equation 2 by equation 3

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In general, the greater the ratio of piston area to rod area, the greater the ratio of extending speed
to retracting speed.

Load-Carrying Capacity during Extension

It should be noted that the load-carrying capacity of a regenerative cylinder during extension
is less than that obtained from a regular double-acting cylinder. The load-carrying capacity
(Fload) for a regenerative cylinder equals the pressure multiplied by piston rod area rather than the
pressure multiplied by piston area. This is due to the same system pressure acting on both sides
of the piston during the extending stroke of the regenerative cylinder.

Thus Fload = PAr

Thus, the power obtained from the regenerative cylinder is less because the extending speed is
increased at the expense of load-carrying capacity.

Application of Regenerative center in Drilling Machine:

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Here a 3-position, 4-way , regenerative center directional control valve is used.

When the DCV is in the spring-centered position, port P is connected to A and B and tank port T
is blocked. In this position pump flow goes to A and flow from rod end of the cylinder also joins
the pump flow to gives rapid spindle advance ( no work is done during this period )

Why does the spring-centered position give rapid extension of the cylinder (drill spindle)? The
reason is simple. Oil from the rod end regenerates with the pump flow going to the blank end. This
effectively increases pump flow to the blank end of the cylinder during the spring-centered mode
of operation. Once again we have a regenerative cylinder. It should be noted that the cylinder used
in a regenerative circuit is actually a regular double-acting cylinder. What makes it a regenerative
cylinder is the way it is hooked up in the circuit. The blank and rod ends are connected in parallel
during the extending stroke of a regenerative center.

When the DCV shifts to 1st position, P is connected to A and B to T gives slow feed (extension)
when the drill starts to cut into the work piece. Similarly when the DCV shifts to 2nd position, P
is connected to B and A is connected to T, since the ring area is less the cylinder will have fast
return motion.

Problem 2.

A double acting cylinder is hooked up in the regenerative circuit. The relief valve setting is 70
bars. The piston area is 0.016 m2 and the rod area is 0.0045 m2. If the pump flow is 0.0013m3/s,
find the cylinder speed and load- carrying capacity for the

a. Extending stroke

b. Retracting stroke.

Solution:

Relief valve pressure setting, p = 70 bars = 70 * 105 N /m2

Piston area, Ap = 0.016 m2

Rod area, Ar = 0.0045 m2

Pump flow, Qp = 0.0013 m3/s

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a) Extending Stroke :

Cylinder speed, vp ext = Qp / Ar

(Regenerative Speed) = 0.0013 / 0.0045 = 0.29 m / s

Load carrying capacity, Fload = p * Ar

= 70 * 105 * 0.0045

= 31500 N = 31.5kN

b) Retracting Stroke :

Cylinder Speed, vp Ret = Qp / (AP – Ar)

= 0.0013 / ( 0.016 - 0.0045 )

= 0.113 m / s

Load carrying capacity, Fload = p * ( AP – Ar )

= 70 * 105 * ( 0.016 - 0.0045)

= 80500 N = 80.5kN

Problem 3.

A double acting cylinder is hooked up in the regenerative circuit. The relief valve setting is 100
bars and the pump flow is 0.0016m3/s. If the regenerative and retracting speed are equal to 0.25m/
s, find the piston and rod area and also load- carrying capacity for the

a. Extending stroke

b. Retracting stroke

Solution

Relief valve pressure setting, p = 100 bars = 100 * 105 N /m2

Pump flow, Qp = 0.0016 m3/s, Speed = 0.25 m/s

We have regenerative cylinder speed, vp ext = Qp / Ar

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Therefore Rod area, Ar = Qp / vp ext

= 0.0016 / 0.25

= 0.0064m2

Piston Area, AP = 2 Ar = 2* 0.0064 = 0.0128 m2

a) Extending Stroke:

Load carrying capacity, Fload = p * Ar

= 100 * 105 * 0.0064

= 64000 N = 64kN

b) Retracting Stroke:

Load carrying capacity, Fload = p * ( AP – Ar )

= 100 * 105 * ( 0.0128 - 0.0065 )

= 67200 N = 67.2kN

Double Pump Hydraulic system (Hi – Lo circuit)

A circuit that uses two pumps, one high-pressure, low-flow pump and the other low-pressure, high-
flow pump. One can find application in a punch press in which the hydraulic ram must extend
rapidly over a large distance with very low pressure but high flow requirements. However, during
the short motion portion when the punching operation occurs, the pressure requirements are high
due to the punching load. Since the cylinder travel is small during the punching operation, the
flow-rate requirements are also low.

The circuit shown eliminates the necessity of having a very expensive high pressure, high-flow
pump. When the punching operation begins, the increased pressure opens the unloading valve to
unload the low-pressure pump. The purpose of the relief valve is to protect the high-pressure pump
from overpressure at the end of the cylinder stroke. The check valve protects the low-pressure

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pump from high pressure, which occurs during the punching operation, at the ends of the cylinder
stroke, and when the DCV is in its spring-centered mode.

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Hydraulic Cylinder Sequencing circuit
A sequence valve causes operations in a hydraulic circuit sequentially. Figure below is an
example where two sequence valves are used to control the sequence of operations of two double-
acting cylinders C1 and C2. When the DCV is shifted into its 1st position, the left cylinder extends
completely, and only when the left cylinder pressure reaches the pressure setting of sequence valve,
the valve opens and then the right cylinder extends. If the DCV is then shifted into its 2nd position,
the right cylinder retracts fully, and then the left cylinder retracts. Hence this sequence of cylinder
operation is controlled by the sequence valves. The spring centered position of the DCV locks both
cylinders in place.

One can find the application of this circuit in press circuit. For example, the left cylinder the
clamping cylinder C1 could extend and clamp a work piece. Then the right cylinder C2, the
punching cylinder extends to punch a hole in the work piece. The right cylinder then retracts the
punch , and then the left cylinder retracts to declamp the work piece for removal. Obviously these
machining operations must occur in the proper sequence as established by the sequence valves in
the circuit.

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CYLINDER SYNCHRONIZING CIRCUITS

Cylinder connected in parallel :

This is a very interesting circuit, which seems to show how two identical cylinders can be
synchronized by piping them in parallel. However, even if the two cylinders are identical, it
would be necessary for the loads on the cylinders to be identical in order for them to extend
in exact synchronization.

If the loads are not exactly identical (as is always the case), the cylinder with the smaller load
would extend first because it would move at a lower pressure level. After this cylinder has fully
completed its stroke, the system pressure will increase to the higher level required to extend the
cylinder with the greater load. It should be pointed out that no two cylinders are really identical.
For example, differences in packing friction will vary from cylinder to cylinder. This alone would
prevent cylinder synchronization for the circuit of Fig. 5.14.

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Cylinders connected in Series :

The circuit of Figure below shows a simple way to synchronize two cylinders. Fluid from the pump
is delivered to the blank end of cylinder 1, and fluid from the rod end of cylinder 1 is delivered to
the blank end of cylinder 2. Fluid returns to the tank from the rod end of cylinder 2 via the DCV.
Thus, the cylinders are hooked in series. For the two cylinders to be synchronized, the piston area
of cylinder 2 must equal the difference between the areas of the piston and rod for cylinder 1. It
should also be noted that the pump must be capable of delivering a pressure equal to that required
for the piston of cylinder 1 by itself to overcome the loads acting on both cylinders. It should be
noted that the pressure at the blank end of cylinder 1 and the rod end of cylinder 2 are equal as per
Pascal’s law.

P1Ap1 - P2(Ap1 – Ar1) = F1

And

P2Ap2 - P3(Ap2-Ar2) = F2

Adding both equations and noting that AP2 = Ap1 – AR1 and that P3 = 0 (due to the drain line to the
tank), we obtain the desired result

P1Ap1= F1 + F2

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Speed control of Hydraulic Cylinder
Speed control of a hydraulic cylinder is accomplished using a flow control valve. A flow control
valve regulate the speed of the cylinder by controlling the flow rate to and of the actuator.

There are 3 types of speed control:

 Meter- in circuit ( Primary control )

 Meter-out circuit ( Secondary control )
 Bleed - off circuit ( By pass control )

Meter – in Circuit : In this type of speed control, the flow control valve is placed between the
pump and the actuator. Thereby, it controls the amount of fluid going into the actuator.

When the directional control valve is actuated to the 1st position, oil flows through the flow control
valve to extend the cylinder. The extending speed of the cylinder depends on the setting (percent
of full opening position) of the flow control valve.

When the directional control valve is actuated to the 2nd position, the cylinder retracts as oil flows
from the cylinder to the oil tank through the check valve as well as the flow control valve.

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Analysis of Extending Speed Control

During the extension stroke, if the flow control valve is fully open, all the flow from the pump
goes to the cylinder to produce maximum cylinder speed. As the flow control valve is partially
closed its pressure drop increases. This causes an increase in pressure p1.

Continued closing of the flow control valve ultimately results in pressure p1 reaching and
exceeding the cracking pressure of the pressure relief valve (PRV). The result is a slower cylinder
speed since part of the pump flow goes back to the oil tank through the PRV setting and the amount
of pump flow that is not desired by the cylinder flows through the PRV. An analysis to determine
the extending speed is given as follows:

The flow rate to the cylinder equals pump flow rate minus the flow rate through the PRV.

Qcyl = Qpump – QPRV

The flow rate through the flow control valve (FCV) is governed by

Pressure p1 = pPRV = Relief valve pressure setting

Also, pressure p3 = 0 (ignoring small frictional pressure drop in drain line from rod end of cylinder
to oil tank).

Pressure p2 can be obtained by summing forces on the hydraulic cylinder.

p2Apiston = Fload or p2 = Fload /Apiston ---(a)

Finally the extending speed of the cylinder is found.

Vcyl = Qcyl / Apiston = QFCV /Apiston ------ (b)

using Eqs. (a) and (b) yields the final result.

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As can be seen by Eq. 1, by varying the setting of the flow control system, and thus the value of
CV, the desired extending speed of the cylinder can be achieved.

Meter – out Circuit

In this type of speed control, the flow control valve is placed between the actuator and the tank
. Thereby, it controls the amount of fluid going out of the actuator.

Meter-in systems are used primarily when the external load opposes the direction of motion of the
hydraulic cylinder. An example of the opposite situation is the case of a weight pulling downward
on the piston rod of a vertical cylinder. In this case the weight would suddenly drop by pulling the
piston rod down if a meter-in system is used even if the flow control valve is completely closed.
Thus, the meter-out system is generally preferred over the meter-in type. One drawback of a meter-

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out system is the possibility of excessive pressure buildup in the rod end of the cylinder while it is
extending. This is due to the magnitude of back pressure that the flow control valve can create
depending on its nearness to being fully closed as well as the size of the external load and the
piston-to-rod area ratio of the cylinder. In addition an excessive pressure buildup in the rod end of
the cylinder results in a large pressure drop across the flow control valve. This produce the
undesirable effect of a high heat generation rate with a resulting increase in oil temperature.

Bleed – off Circuit

In this type of speed control, the flow control valve is placed between the pressure line and return
line. Thereby, it controls the fluid by bleeding off the excess not needed by the working cylinder.

This type of flow control is much more efficient than the inlet restricting type for meter-in, because
the bypass feature allows fluid to be exhausted to the tank at just slightly higher pressure than that
necessary to do the work. With the meter-in type, pump delivery not used would discharge over
the main relief valve at maximum pressure.

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Problem 4

An actuator forward speed is controlled by a meter-in circuit. The pressure setting of relief valve
is 50 bar and the pump discharge = 30 litres /min. The cylinder has to carry a load of 3600 N during
the forward motion. The area of piston is 15 cm2 and rod area = 8cm2. The flow control valve is
set to allow only 10 litres/ min. Calculate the power input to motor, forward speed and return speed
and efficiency of the circuit.

Speed control of Hydraulic Motor

Figure below shows a circuit where speed control of a hydraulic motor ( Bi -directional motor) is
accomplished using a flow control valve to control the fluid flow to the motor.

In the spring-centered position of the tandem four-way valve, the motor is hydraulically locked.
When the four-way valve is actuated into the 1st position, the motor rotates in one direction. Its

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speed can be varied by adjusting the setting of the throttle of the flow control valve. In this way
the speed can be infinitely varied as the excess oil goes to the tank through the pressure relief
valve. When the four-way valve is deactivated, the motor stops suddenly and becomes locked.
When the 2nd position of the four-way valve is in operation, the motor turns in the opposite
direction. The pressure relief valve provides overload protection if, for example, the motor
experiences an excessive torque load.

M = Bi-directional Hydraulic motor ; P = Pump ; T = Tank; F = Filter

R = Relief Valve; FCV = Flow control Valve

D =3-position, 4 way ,Tandem center, Manually operated and Spring Centered DCV

The speed of hydraulic motor can be controlled either by meter-in control or meter- out
control.(assignment)

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Hydrostatic Transmission (HST)

These are special cases of energy transmission system. It consists of a drive with hydraulic energy
as input. Hydraulic motor convert hydraulic energy to mechanical energy. Hydrostatic
transmission is a whole unit in which pumps and motors are designed to match (the speed torque
characteristics) to get optimum transmission. The HST can be open or closed circuit

Open circuit HST

They are called open circuit drives because the pump draws its fluid from a tank. Its output is then
directed to a hydraulic motor and discharged from the motor back to the tank. In the closed circuit
drive, exhaust oil from the motor is returned directly to the pump inlet.

The figure below shows a closed circuit that allows either direction of motor rotation. The feed
pump is provided for replenishing the fluid in the circuit. The check valves prevent the oil flow
from the main pump to the feed pump. Here two relief valve R 1 and R2 are used to protect the
main pump in both the direction of rotation. The motor speed is varied by changing the pump
displacement. The torque capacity of the motor can be adjusted by the pressure setting of the relief
valve. Closed circuit drives are available as completely integrated units with all the controls and
valving enclosed in a single, compact housing.

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Fluid power system Eng Mpiima Isaac