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Chapter 3

Here are the key steps to solve this problem: a) Extending stroke: - Total flow (QT) = Pump flow (QP) + Rod flow (QR) = 25 gpm + 10gpm = 35 gpm - Speed (V) = Total flow / Piston area = 35 gpm / 20 in^2 = 1.75 ft/sec - Load capacity = Relief pressure x Rod area = 1500 psi x 10 in^2 = 15,000 lbs b) Retracting stroke: - Speed = Pump flow / (Piston area - Rod area) = 25 gpm / (20 in^2 - 10 in^2) = 1.25 ft/sec -

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64 views31 pages

Chapter 3

Here are the key steps to solve this problem: a) Extending stroke: - Total flow (QT) = Pump flow (QP) + Rod flow (QR) = 25 gpm + 10gpm = 35 gpm - Speed (V) = Total flow / Piston area = 35 gpm / 20 in^2 = 1.75 ft/sec - Load capacity = Relief pressure x Rod area = 1500 psi x 10 in^2 = 15,000 lbs b) Retracting stroke: - Speed = Pump flow / (Piston area - Rod area) = 25 gpm / (20 in^2 - 10 in^2) = 1.25 ft/sec -

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tekitech443
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CHAPTER 3

Design of Hydraulic Systems


INTRODUCTION
A hydraulic circuit is a group of components such
as pumps, actuators, control valves, arranged so
that they perform a specific useful task.
Three important considerations when analyzing or
designing hydraulic circuits
1. Safety of operation

2. Performance of desired function

3. Efficiency of operation
2
• Hydraulic circuits are developed using graphic
symbols for all components. American National
Standards Institute (ANSI) symbols will be used
here.
Control of a Single-acting Hydraulic Cylinder
fig. shows a two-position, three-way, manually
actuated, spring-offset directional control valve
(DCV) controlling the operation of a single acting
cylinder.
• …..
• The spring in the rod end of the
cylinder retracts the piston as oil
from the blank end drains back to
the tank.
• When the valve is actuated
manually in to the left envelope
flow path configuration, pump flow
extends the cylinder.
• At full extension, pump flow goes
through the PRV
Control of a Double-Hydraulic Cylinder
shows the circuit used to control a double-acting
hydraulic cylinder
• When the four-way valve is in •
its spring-centered position,
cylinder is hydraulically
locked, pump unloaded back to
the tank
• When manually operated to the
left envelop configuration, oil
flows to the blank end of the
cylinder extending the cylinder
rod against the external load.
Also oil in the rod end flows
to the tank through valve B
…
• In the right envelope
configuration oil flows to the
rod end thus initiating retraction
and flow of oil out of the blank
end to the tank.
• At the end of the strokes, if
there is no demand of oil by the
system, the pump flow goes to
the tank through the pressure
relief valve. PRV protects from
overload too.
REGENERATIVE CYLINDER CIRCUIT
shows a regenerative circuit that is used to speed up
the extending speed of a double-acting cylinder.

• Left envelope configuration has


the pump flow and the exhaust
flow flowing to the blank end
(volume flow rate is large).
• Right envelope configuration
has the exhaust from the blank
end to the tank. The pump
flow bypasses the DCV directly
to the rod compartment (since
one of the ports is closed).
Cylinder Extending Speed
During extension the flow from the rod end (QR) regenerates
with the pump flow (QP) to provide a total flow rate (QT).
QT = QP + QR or
QP = QT - QR
For extension velocity VP,ext
QP =APVP,ext - (AP –Ar) VP,ext
The extending speed
QP
VP ,ext 
Ar

The small rod area gives a large extending speed. It


can be greater than the retracting speed if the rod
area is made small enough
Ratio of Extending and Retracting Speeds

The retraction speed is given by


QP
VP ,ret 
AP  Ar

The ratio of the two speeds will be


VP ,ext QP / Ar AP  Ar AP
   1
VP ,ret QP /( AP  Ar ) Ar Ar

The two speeds will be the same when AP = 2Ar 10


Load-Carrying Capacity During Extension

As the pressure is the same in both faces during


extension, the load carrying capacity becomes

Fload,ext = pAP-p(AP-Ar) = pAr

The load is reduced at the expense of the speed.

11
Example
A double-acting cylinder is hooked up in the
regenerative circuit of shown in the figure. The
cracking pressure for the relief valve is 6.895x106pa.
The piston area is 161.29 cm2 and the rod area is
45.16cm2. the pump flow is 75.71 LPM. Find the
cylinder speed, load carrying capacity, and power
delivered to the load (assuming the load equals the
cylinder load-catrying capacity) during the
a) Extending stroke
b) Retracting stroke
Quize
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
PUMP-UNLOADING CIRCUIT

• The unloading valve

unloads the pump at the

ends of the extending

and retraction strokes

as well as in the spring-

centered position of the

DCV.
Fig. Pump-unloading circuit
HYDRAULIC CYLINDER SEQUENCING CIRCUITS
Sequence valves prioritize the operation system.

shows two sequence valves to operate two double acting


cylinders. The spring-centered position of the DCV locks both
cylinders in place.
• In the extreme left envelope configuration the left
cylinder (C1) extends. At the end of extension
pressure builds up and the right sequencing valve
(CQ2) opens and the right cylinder (C2) extends.
• In the extreme
right envelope
configuration the
right cylinder (C2)
retracts first and
then the left
cylinder (C1)
retracts.
 One application could be the use of the left cylinder for
clamping and the right cylinder for drilling.
CYLINDER SYNCHRONIZING CIRCUITS
Cylinders Connected in
Parallel
shows two identical cylinders
expected to be synchronized.
Synchronization requires
identical loads. If not, the lower
load cylinder will extend first
since it requires less pressure. It
should be pointed out that no two
cylinders are really identical.
Packing friction will differ from
cylinder to cylinder. 17
Cylinders Connected in Series
The DCV at the left envelope
oil is delivered to the blank end
of cylinder 1. As it extends
fluid is delivered to the blank
end of cylinder2. For the
cylinders to be synchronized the
piston area of cylinder 2 must
equal the effective area of the
rod end of cylinder 1 and this
can easily be proved by
applying continuity equation.
Fig. Cylinders hooked in series will operate
18
in synchronization
Which states that the rate at which fluid leaves the rod
end of cylinder 1 must equal the rate at which fluid
enters cylinder 2. we have for a hydraulic fluid
Qout(cyl 1) = Qin(cyl 2)
Since Q = Av where A is the effective
(Aeff v)cyl 1 = (Aeff v)cyl 2
(AP1 – AR1) v1 = AP2 v2
Since for synchronization v1 = v2

For the same speed AP1 – AR1 = AP2


• The pressure supplied must enable the two cylinders to
handle their respective loads.
• The pressures are equal at the blank end of cylinder 2 and
at the rod end of cylinder 1 per Pascal’s law
• Force balance on cylinders 1 and 2 gives
p1AP1 –p2(AP1-AR1) = F1

p2AP2 – p3(AP2 –AR2) = F2

Since AP2 = AP1 – AR1 and p3 = 0 (due to the drain line to the
tank)
The above equation will give
p1AP1 = F1 + F2
SPEED CONTROL OF A HYDRAULIC
CYLINDER
Speed is controlled by controlling the flow to the
cylinder. Basically meter-in or meter-out control
systems are used.
Infigs\fig..pptx meter-in control is used.
• The extending speed is dependent on the setting of
the FCV (operational when DCV is in left envelope
or actuated mode)
21
Analysis of Extending Speed Control
Flow control reduces the flow rate which in turn will
raise the pressure of the fluid before the FCV.
Continued closing results in p1 reaching and
exceeding the cracking pressure of the PRV. This
results in slower speed and a partial flow of fluid to
the tank through the PRV.
Qcyl = Qpump – QPRV
p p1  p2
Q FCV  Cv  Cv
SG SG
p1 = pPRV = PRV setting; also p3 ≈ 0
22
Force balance on the cylinder will give
p2Apiston = Fload or p2 = Fload/Apiston
Also the speed of the piston given by
Vcyl = Qcyl/Apiston = QFCV/Apiston
And after substitution of QFCV will result in
cv p PRV  Fload / A piston
Vcyl 
A piston SG

23
Quize 2
For the meter-in system of the figure the following data are given:
 Valve capacity coefficient = 1.442  Specific gravity of the oil = 0.9
lpm/√kPa)  Pressure relief valve setting =
 Cylinder piston diameter = 50 mm 9652.66 kPa
 Cylinder load = 17,800 N Determine the cylinder speed
DOUBLE-PUMP HYDRAULIC SYSTEM
COUNTERBALANCE VALVE APPLICATION
Quize
A double-acting cylinder is hooked up in the
regenerative circuit of shown in the figure. The relief
valve setting is 1500 psi. The piston area is 20in2 and
the rod area is 10 in2. if the pump flow is 25 gpm. Find
the cylinder speed, load carrying capacity for the
a) Extending stroke
b) Retracting stroke

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