HYDRAULIC CIRCUITS AND APPLICATIONS

CHAPTER 7: HYDRAULIC CIRCUITS AND APPLICATIONS

INTRODUCTION

In this chapter, hydraulic circuits that primarily do not use basic electrical control devices such

as push-button switches, pressure switches, limit switches, solenoids, relay and timers will be

discussed. A hydraulic circuit is a group of components such as a pump, control valves,

actuators and fluid conductors arranged together to perform a useful task. There are three

important considerations when in designing hydraulic circuits.

a) Safety of operation.

b) Performance of the desired functions.

c) Efficiency of operation.

LEARNING OBJECTIVES

Upon completion of this chapter, the students should be able to:

1) describe the operation of hydraulic circuits drawn using graphic symbols for all

components.

2) draw and describe the basic design of hydraulic circuits to perform desired functions.

3) describe the various types of fittings used to connect hydraulic components to

conductors.

4) discuss the safety and maintenance aspect of the hydraulic system.

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7.1 BASIC CIRCUIT DIAGRAMS AND APPLICATIONS

The following discussion will cover circuits that represent basic hydraulic technology.

7.1.1 CONTROL OF SINGLE-ACTING CYLINDER

Figure 7.1 illustrates of how a two-position, three-way, manually actuated,

spring-offset directional control valve (DCV) can be used to control the operation of a

single-acting cylinder. In the spring-offset mode, fully pump flow goes to the tank via

the pressure relief valve. The spring in the rod end of the cylinders retracts the piston

as oil from the blank end drains back to the tank. When the valve is manually actuated

into its left envelope flow path configuration, pump flow 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 shifts into its spring-offset mode.

Figure 7.1: Control of a single acting hydraulic cylinder.

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7.1.2 CONTROL OF A DOUBLE ACTING HYDRAULIC CYLINDER

Figure 7.2 illustrates a circuit used to control a double-acting hydraulic cylinder.

The operation is described as follows:

 When the four-way valve is in its spring-centered position (tandem design), the

cylinder is hydraulically locked. Also the pump is unloaded back to the tank at

essentially atmospheric pressure.

 When the four-way valve is actuated into the flow path configuration of the left

envelope, the cylinder is extended against its load force Fload as oil flows 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 could not extend

if this oil is not allowed to leave the rod end of the cylinder.

 When the four-way valve is deactivated, the spring centered envelope prevails, and

the cylinder is once again hydraulically locked.

 When the four-way valve is actuated into the right envelope configuration, the

cylinder retracts as oil flows from port P through port B. Oil in the blank end is returned

to the tank via the flow path from port A to port T.

 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.

Figure 7.2: Control of a double-acting hydraulic cylinder.

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7.1.3 REGENERATIVE CYLINDER CIRCUIT

Figure 7.3(a) shows a regenerative circuit that is used to speed up the

extending speed of a double-acting hydraulic cylinder. Note that the pipelines to both

ends of the hydraulic cylinder are connected in parallel and that one of the ports of the

four-way valve is blocked. A common method used to block a valve port is to simply

screw a threaded plug into the port opening. 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 via the right envelope during retraction. In this mode, fluid from the

pump bypasses the DCV and enters the rod end of the cylinder. Fluid in the blank end

drains back to the tank through the DCV as the cylinder retracts.

Figure 7.3(a): Regenerative circuit.

When the DCV is shifted into its left envelope configuration, the cylinder extends as

shown in Figure 7.3(b). 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 at the

blank end of the cylinder.

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Figure 7.3(b): Partial circuit showing flow paths during cylinder extension stroke.

Drilling Machine Application

Figure 7.4 shows an application using a four-way valve having a spring centered

design with a closed tank port and a pressure port open to outlets ports A and B.

The application is for a drilling machine, whereby the following operations take place:

1) The spring centered position gives rapid spindle advance (extension).

2) The left envelope modes give slow feed (extension) when the drill starts to cut into

the workpiece.

3) The right envelope mode retracts the piston.

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Figure 7.4: Drilling machine application.

EXERCISE 7.1

Referring to the drilling machine application illustrated in Figure 7.4, why does the spring

centered position gives a rapid extension to the cylinder (drill spindle)?

Answer

The reason is simple: Oil from the rod end regenerates with the flow going to the blank
end. This effectively increases pump flow to the blank end of the cylinder during the spring
centred mode of operation. Once again, we have a regenerative cylinder. It should be
noted that the cylinder used in 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 cylinder. The retraction mode is the same as a regular double-acting cylinder.

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7.1.4 PUMP UNLOADING CIRCUIT

In Figure 7.5, it illustrates a circuit using an unloading valve to unload a pump.

The unloading valve opens when the cylinder reaches the end of its extension stroke

because the check valve keeps a higher pressure oil in the pilot line of the unloading

valve. When the DCV is shifted to retract the cylinder, the motion of the piston reduces

the pressure in the pilot line of the unloading valve. This resets the unloading valve

until the cylinder is fully retracted, at the point which the unloading valve unloads the

pump. Thus, the unloading valve unloads the pump at the end of the extending and

retracting strokes as well as in the spring centered position of the DCV.

Figure 7.5: Pump unloading circuit.

7.1.5 DOUBLE-PUMP HYDRAULIC SYSTEM

Figure 7.6 shows a circuit that uses high pressure, low flow pump in conjunction

with low pressure, high flow pump. A typical application is a sheet metal punch press

in which the hydraulic ram (cylinder) must extend rapidly over a great distance with

very low pressure but high flow rate requirements. This rapid extension of the cylinders

occurs under no external load as the punching tool (connected to the end of the

cylinder piston rod) approaches the sheet metal strip to be punched. However, during

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the short motion portion when the punching operation occurs, the pressure

requirements are high due to the punching load.

During the punching operation, the cylinder travel is small thus the flow rate

requirements are low. The circuit shown eliminates the necessity of having a very

expensive high pressure, high flow pump. When the punching operation begins, the

increase 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 and when the DCV is in its spring centered mode. The

check valve protects the low pressure 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.

Figure 7.6: Double-pump hydraulic system

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7.1.6 COUNTERBALANCE VALVE APPLICATION

Figure 7.7 illustrates that use of a counterbalance or back pressure valve to

keep a vertically mounted hydraulic cylinder in the upward position while the pump is

idling. The counterbalance valve is set to open at somewhat above the pressure

required to prevent the vertical cylinder from descending due to the weight of its load.

This permits the cylinder to be forced downward when pressure is applied on the top.

The open center directional control valve unloads the pump. The DCV is a solenoid-

actuated, spring centered valve with an open-center flow path configuration.

Figure 7.7: Counterbalance valve application.

7.1.7 HYDRAULIC CYLINDER SEQUENCING CIRCUIT

A sequence valve causes operations in a hydraulic circuit to be sequential.

Figure 7.8 illustrates an application example where two sequence valves are used to

control the sequence of operations of two double-acting cylinders. When the DCV is

shifted into its left envelope mode, the left cylinder extends completely, and the right

cylinder extends. If the DCV is then shifted into its right envelope mode, the right

cylinder fully retracts, and then the left cylinder retracts. This sequence of cylinder
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operation is controlled by the sequence valves. The spring-centered position of the

DCV locks both cylinders in place.

Application

One application of this circuit is a production operation. For example, the left cylinder

could extend and clamp a workpiece via a power vise jaw. Then the right cylinder

extends to drive a spindle to drill a hole in the workpiece. The right cylinder then retracts

the drill spindle, and then the left cylinder retracts to release the workpiece for removal.

Obviously these machining operations must occur in the proper sequence as

established by the sequence valves in the circuit.

Figure 7.8: Hydraulic cylinder sequencing circuit.

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7.1.8 AUTOMATIC CYLINDER RECIPROCATING SYSTEM

Figure 7.9 illustrates a circuit that produces continuous reciprocation of a

hydraulic cylinder. This is accomplished by using two sequence valves, each of which

senses a stroke completion by the corresponding build-up pressure. Each check valve

and corresponding pilot line prevents shifting of the four-way valve until the particular

stroke of the cylinder has been completed. The check valves are needed to allow pilot

oil to leave either end of the DCV while pilot pressure is applied to the opposite end.

This permits the spool of the DCV to shift as required.

Figure 7.9: Automatic cylinder reciprocating system.

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7.1.9 TWO-HAND SAFETY SYSTEM

The safety circuit shown in Figure 7.10 is designed to protect an operator from

injuries. For the circuit function (extension and retraction of the cylinder), the operator

must press both manually actuated valves via the push-buttons. Furthermore, the

operator cannot circumvent (by-pass) this safety feature by tying down one of the

buttons since it is necessary to release both buttons to retract the cylinder. When the

buttons are pressed, the main three-position directional control valve is pilot-actuated

to extend the cylinder. When both push buttons are released, the cylinder retracts.

Figure 7.10: Two-hand safety circuit.

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7.1.10 HYDRAULIC MOTOR BRAKING SYSTEM

When using a hydraulic motor in a fluid power system, consideration should be

given to the type of loading that the motor will experience. A hydraulic motor may be

driving a machine having a large inertia. This would create a flywheel effect on the

motor, and stopping the flow of fluid to the motor would cause it to act as a pump. In a

situation such as this, the circuit should be designed to provide fluid to the motor while

it is pumping to prevent it from pulling in air. In addition, provisions should be made for

the discharge fluid from the motor to be returned to the tank either unrestricted or

through a relief valve. This would stop the motor rapidly but without damage to the

system. Figure 7.11 shows a hydraulic motor braking circuit that possesses these

desirable features for either direction of motor rotation.

Figure 7.11: Hydraulic motor braking system circuit.

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7.2 CONNECTION METHODS FOR HYDRAULIC CIRCUITS

In hydraulic system, the fluid flows through a distribution system consisting of

conductors and fittings, which carry the fluid from the reservoir through operating

components and back to the reservoir. Since power is transmitted throughout the

system by means of these conducting lines (conductors and fittings used to connect

system components), they must be properly designed in order for the total system to

function properly. Hydraulic systems use primarily four types of conductors:

a) steel pipes

b) steel tubing

c) plastic tubing

d) flexible hoses

7.2.1 STEEL PIPES

Size Designation

Pipes and pipe fittings are classified by nominal size and schedule number as shown

in Table 7.1 below. The schedule provided are for the pipe inside diameter of 40 mm,

80 mm, and 160 mm, which are the most commonly used for hydraulic systems. Note

that for each nominal size, the outside diameter does not change. To increase wall

thickness, the next larger schedule number is used. Also observe that the nominal size

is neither the outside nor the inside diameter. Instead, the nominal pipe size indicates

the thread size for the mating connections.

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Table 7.1: Common pipes size.

7.2.2 FLEXIBLE HOSE

The fourth major type of hydraulic conductor is the flexible hose as shown in

Figures 7.12, which is used when hydraulic components such as actuators are

subjected to movements. Hose assemblies of virtually any length and with various end

fittings are available from manufacturers.

Figure 7.12: Flexible hose with permanently attached end fittings (a) Straight fitting,

(b) 45° elbow fitting, and (c) 90° elbow fitting.

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Hose Routing and Installation

Care should be taken in changing fluid in hoses since the hose and fluid materials must be

compatible. Flexible hose should be installed so there is no kinking during operation of the

system. There should always be some slack to relieve any strain and allow for the absorption

of pressure surges. It is poor practice to twist the hose and use long loops in the plumbing

operation. It may be necessary to use clamps to prevent tangling of the hose with moving

parts. If the host is subject to rubbing, it should be encased in a protective sleeve. Figure 7.13

provides basic information on hose routing and installation procedures.

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Figure 7.13: Hose routing and installation procedures.

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7.3 SAFETY CONSIDERATIONS AND MAINTENANCE

7.3.1 SAFETY CONSIDERATIONS

There should be no compromise in safety when hydraulic circuits are designed,

operated, and maintained. However, human errors are unavoidable, and accidents can

occur, resulting in injury to the operating and maintenance personnel. This can be

greatly reduced by eliminating all unsafe conditions dealing with the operation and

maintenance of the system. Many safe practices have been proven effective in

preventing safety hazards, which can be harmful to the health and safety of personnel.

Since the materials used in this module are mostly extracted from the United

States resources, hence, it follows the Occupational Safety and Health (OSHA) of the

United States Department of Labor, which describes and enforces safety standards at

the industry location where the hydraulic equipment is operated. The detailed

information on OSHA standards and requirements should be referred to the General

Industry Regulations for applying Occupational Safety and Health Standards, 29 CFR

1910 OSHA. The regulations are dealing with the following standards:

1) Workplace standards: In this category are included the safety of floors, entrance

and exit areas, sanitation and fire protection.

2) Machine and equipment standards: Important items are machine guards,

inspection and maintenance techniques, safety devices and the mounting,

anchoring, and grounding of fluid power equipment. One big concern is noise level

produced by operating equipment.

3) Material standards: These standards cover item such as toxic fumes, explosive

dust particles, and excessive atmospheric contamination.

4) Employee standards: Concern here include employee training, personnel

protective equipment and medical and first aid service.

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5) Power source standards: Standards are applied to power sources such as

electrohydraulic, pneumatic and steam supply system.

6) Process standards: Many industrial processes are included such as welding,

spraying, abrasive blasting, part dipping, and machining.

7) Administrative regulations: Industry has many administrative responsibilities which

it must meet. These include the displaying of OSHA poster stating the rights and

responsibilities of both the employer and employee. Industry is also required to

keep safety records on accident, illnesses, and other exposure occurrences. An

annual summary must also be posted.

It is also important that safety must be incorporated into hydraulic systems to ensure

compliance with OSHA regulations. The basic rule to follow is that there should be

no compromise when it comes to the health and safety of the people at their place of

employment.

7.3.2 MAINTENANCE

The following is a list of the most common causes of hydraulic system breakdown;

 Clogged or dirty oil filters.

 Inadequate supply of oil in the reservoir.

 Leaking seal.

 Loose inlet lines that cause the pump to take in air.

 Incorrect type of oil.

 Excessive oil temperature.

 Excessive oil pressure.

Most of these types of problems can be eliminated if a planned preventive

maintenance program is undertaken. This starts with the fluid power designs in the

selection of high quality, and properly sized components. The next step is the proper

assembly of the various components. This includes applying the correct amount of
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torque to the various tube fittings to prevent leaks and, at the same time, will not

distort the fitting. Parts should be cleaned as they are assembled, and the system

should be completely flushed with clean oil prior to putting it into service. It is

important for the total system to provide easy access to components requiring

periodic inspection such as filters, strainers, sight gauges, drains and fill plugs, flow

meters, as well pressure and temperature gauges.

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