Lesson 7: Cylinders

Lesson 7: Cylinders

Basic Hydraulic Systems

• Hydraulic Tank
• Hydraulic Fluids
• Hydraulic Pumps and Motors
• Pressure Control Valves
• Directional Control Valves
• Flow Control Valves
• Cylinders

Introduction
Cylinders are basically linear actuators. Their outputs are straight
line motion or force. The most common types are single acting
cylinders and double acting cylinders.
Objectives
Upon completion of this lesson the student will:

1. Identify the two basic types of hydraulic cylinders.

2. State the function of the two basic types of hydraulic
cylinders.
3. Identify the basic cylinder components.
Unit 3 3-7-2 Hydraulic Fundamentals
Lesson 7

CYLINDER
BODY BORE SEAL
TANK

LOAD

HEAD END ROD END

PISTON ROD
FROM
CONTROL VALVE

Fig. 3.7.1 Single Acting Cylinder

Single Acting Cylinders

Figure 3.7.1 shows a single acting cylinder.
The tubular outer housing is the cylinder body. Inside the cylinder
body are the piston, piston seal and the rod. The bore refers to the
inside diameter of the cylinder body. The head end (sometime called
the blind end) refers to the piston end of the cylinder. The rod end
refers to the end from which the rod extends and retracts.

GRAVITY

TO CONTROL
VALVE
FROM CONTROL
VALVE

EXTEND ROD RETRACT ROD

Fig. 3.7.2 Vertical Lift Gravity Return Operation

Vertical Lift Gravity Return Operation

The single acting cylinder is often used on vertical lift gravity return
operations as shown in Figure 3.7.2. The control valve directs oil to
the head end of the cylinder. The oil pressure acts upon the piston to
extend the rod and lift the load. Gravity acting on the load is used to
retract the rod and lower the load.
Unit 3 3-7-3 Hydraulic Fundamentals
Lesson 7

PISTON PISTON ROD

SEAL
HEAD ROD
END END
LOAD

FROM TO
CONTROL VALVE CONTROL VALVE

Fig. 3.7.3 Double Acting Cylinders

Double Acting Cylinders

Figure 3.7.3 shows a double acting cylinder. The double acting
cylinder is the most common hydraulic actuator used today. The
double acting cylinder is used on the implement, the steering and
other systems where the cylinder is required to do work in both
directions.
Since tie rod cylinders are the most common double acting cylinder,
the National Fluid Power Association (NFPA) guidelines are used for
the standards in bore size, mounting style and overall dimensions.
This allows tie rod cylinders from different manufacturers to be
interchangeable when they have the same description. However, it
must be remembered that cylinders may be equal in size without
being equal in quality.
Unit 3 3-7-4 Hydraulic Fundamentals
Lesson 7

EFFECTIVE
EFFECTIVE AREA
BORE AREA

FROM CONTROL TO CONTROL TO CONTROL FROM CONTROL

VALVE VALVE VALVE VALVE

Fig. 3.7.4 Effective Area of a Cylinder

Effective Area of a Cylinder

The bore size of the cylinder refers to the inside diameter of the
cylinder. A cylinder with a large bore size creates a larger volume
per unit of length than a cylinder with a small bore size. The large
bore size cylinder takes more oil to move the piston the same
distance than the small bore size cylinder. Therefore for a given
flow rate, a large bore size cylinder moves slower than a small bore
size cylinder.
The effective area of a cylinder is the surface area of the piston and
piston seal upon which the oil pushes. Because one end of the rod
attaches to the piston and the opposite end extends out of the
cylinder, the rod end effective area is less than the head end effective
area. The oil can not push against the area of the piston that is
covered by the rod.
The volume of oil needed to fill the rod end of the cylinder is less
than the volume of oil needed to fill the head end of the cylinder.
Therefore, the cylinder rod retracts faster than the cylinder rod
extends for a given flow rate.
Unit 3 3-7-5 Hydraulic Fundamentals
Lesson 7

PISTON HEAD SEAL ROD

SEAL ('O' RING) GLAND

LOAD

ROD WIPER
SEAL SEAL

Fig. 3.7.5 Seals

Seals
Seals are used in various places throughout the cylinder as shown in
Figure 3.7.5.
The piston seal is used between the piston and the cylinder wall. The
design is such that oil pressure spreads the seal against the cylinder
wall, thus the greater the pressure the greater the sealing force.
The head seal ('O' ring) prevents oil escaping between the rod gland
and the cylinder wall.
The rod seal is a "U" shaped or u-cup shaped seal that prevents oil
escaping between the rod and the rod gland and wipes the oil off the
rod as the rod is extended from the cylinder.
The wiper seal is fitted to the cylinder and prevents dirt or grit being
drawn into the cylinder as the cylinder rod retracts.
Seals are made of polyurethane, nitrile or viton. The material should
be verified to be compatible with the fluid used and the operating
conditions.
Unit 3 3-7-6 Hydraulic Fundamentals
Lesson 7

HEAD END ROD END

RETURN OIL RETURN OIL
PASSAGE PASSAGE

LOAD

HEAD END ROD END

SNUBBER SNUBBER
(DAMPER) (DAMPER)

Fig. 3.7.6 Cylinder Equipped with Snubbers

Cylinders Equipped with Snubbers (Dampers)

Figure 3.7.6 shows a cylinder equipped with snubbers (dampers).
When a moving cylinder runs into a dead end (as at the end of the
cylinder's stroke), the concussion is called "shock loading." When
cylinders are subject to shock loading, snubbers are used to minimize
the effect.
When the piston approaches full stroke, the snubber moves into the
return oil passage and restricts the return oil flow from the cylinder.
The restriction causes an increase in the return oil pressure between
the return oil passage and the piston. The increase in oil pressure
provides a "cushioning effect" which slows the piston and minimizes
the shock that occurs at full stroke.
Some cylinders may require a head end snubber, some may require a
rod end snubber, while others may require both head end and rod end
snubbers.
Unit 3 -1- Hydraulic Fundamentals
Instructor Copy Lab 3.7.1

Instructor Copy: Lab 3.7.1

Name _________________________

SYSTEM
PRESSURE
GAUGE
1 2
P A

T B

SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 3.7.7 Circuit

LAB 3.7.1: COMPARE THE OPERATING SPEEDS OF TWO CYLINDERS

Purpose
To compare operating speeds of two cylinders of known bore sizes.
Material Needed
Basic Hydraulic Training Unit.
Stop Watch
Procedure
1. Construct the circuit shown in Figure 3.7.7 include the 1 1/16" bore cylinder.
2. Adjust the system pressure to 5856 kPa (850 psi).
3. Turn ON the training unit.
4. Adjust the flow control valve so that the flow meter reading is .2 gpm.
5. With the cylinder rod fully retracted, fully extend the cylinder rod. Record the extension time
in the chart (Figure 3.7.8).

CYLINDER EXTEND RETRACT

TIME TIME
1 1/16"
BORE 9.4 sec 7.5 sec
1 1/2"
BORE 14.5 sec 12.5 sec
Fig. 3.7.8 Chart
Unit 3 -2- Hydraulic Fundamentals
Instructor Copy Lab 3.7.1

LAB 3.7.1: COMPARE THE OPERATING SPEEDS OF TWO CYLINDERS (continued)

6. With the cylinder rod fully extended, fully retract the cylinder rod. Record the retraction time
in the chart (Figure 3.7.8).
7. Time the cylinder extension and retraction times again to confirm your data.
8. Turn OFF the training unit.
9. Disconnect the 1 1/16" bore cylinder and connect the 1 1/2" bore cylinder.
10. Turn ON the training unit.
11. With the cylinder rod fully retracted, fully extend the cylinder rod. Record the extension time
in the chart (Figure 3.7.8).
12. With the cylinder rod fully extended, fully retract the cylinder rod. Record the retraction time
in the chart (Figure 3.7.8).
13. Time the cylinder extension and retraction times again to confirm your data.
14. Turn OFF the training unit and disconnect the hoses.
15. Which time was fastest for the 1 1/16" bore cylinder?
The retract time
16. Which time was fastest for the 1 1/2" bore cylinder?
The retract time
17. State the reason for the answer in questions 15 and 16.
The cylinder rod takes up space inside the cylinder as the cylinder retracts. Therefore, the
volume of oil needed to fill the cylinder when the cylinder is retracting is less than the
volume of oil needed to fill the cylinder when the cylinder is extending. For a given flow
rate, the cylinder fills faster when retracting than when extending. For a given flow rate the
cylinder moves faster when retracting than when extending.
Unit 3 -1- Hydraulic Fundamentals
Student Copy Lab 3.7.1

Student Copy: Lab 3.7.1

Name _________________________

SYSTEM
PRESSURE
GAUGE
1 2
P A

T B

SYSTEM 2
RELIEF
VALVE
BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 3.7.7 Circuit

LAB 3.7.1: COMPARE THE OPERATING SPEEDS OF TWO CYLINDERS

Purpose
To compare operating speeds of two cylinders of known bore sizes.
Material Needed
Basic Hydraulic Training Unit.
Stop Watch
Procedure
1. Construct the circuit shown in Figure 3.7.7 include the 1 1/16" bore cylinder.
2. Adjust the system pressure to 5856 kPa (850 psi).
3. Turn ON the training unit.
4. Adjust the flow control valve so that the flow meter reading is .2 gpm.
5. With the cylinder rod fully retracted, fully extend the cylinder rod. Record the extension time
in the chart (Figure 3.7.8).

CYLINDER EXTEND RETRACT

TIME TIME
1 1/16"
BORE
1 1/2"
BORE
Fig. 3.7.8 Chart
Unit 3 -2- Hydraulic Fundamentals
Student Copy Lab 3.7.1

LAB 3.7.1: COMPARE THE OPERATING SPEEDS OF TWO CYLINDERS (continued)

6. With the cylinder rod fully extended, fully retract the cylinder rod. Record the retraction time
in the chart (Figure 3.7.8).
7. Time the cylinder extension and retraction times again to confirm your data.
8. Turn OFF the training unit.
9. Disconnect the 1 1/16" bore cylinder and connect the 1 1/2" bore cylinder.
10. Turn ON the training unit.
11. With the cylinder rod fully retracted, fully extend the cylinder rod. Record the extension time
in the chart (Figure 3.7.8).
12. With the cylinder rod fully extended, fully retract the cylinder rod. Record the retraction time
in the chart (Figure 3.7.8).
13. Time the cylinder extension and retraction times again to confirm your data.
14. Turn OFF the training unit and disconnect the hoses.
15. Which time was fastest for the 1 1/16" bore cylinder?

16. Which time was fastest for the 1 1/2" bore cylinder?

17. State the reason for the answer in questions 15 and 16.
Unit 3 -1- Hydraulic Fundamentals
Instructor Copy Lab 3.7.2

Instructor Copy: Lab 3.7.2

Name _________________________

NUT AND
WASHERS
CYLINDER
SYSTEM
RELIEF 2
PRESSURE SPRING
VALVE
GAUGE
WASHER

1 1

SYSTEM
RELIEF
2
VALVE

BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 3.7.9

LAB 3.7.2: COMPARE THE OPERATING FORCES OF TWO CYLINDERS

Purpose
To compare the operating forces of two cylinders of known bore sizes.
Material Needed
Basic Hydraulic Training Unit
Procedure
1. Build the circuit shown in Figure 3.7.9.
2. Reverse the hoses to the cylinder (rod end hose to the head end and the head end hose to the
rod end).
3. Turn the cylinder relief valve fully counter-clockwise.
4. Adjust the system pressure to 5856 kPa (850 psi).
5. Turn ON the training unit.
6. Using the cylinder relief valve, increase the system pressure enough to fully extend the rod on
the 1 1/16" bore cylinder and install the load spring.
7. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
8 Turn OFF the training unit.
9. Connect the cylinder hoses as shown in Figure 3.7.9.
10. Turn ON the machine.
11. Turn the cylinder relief valve screw clockwise until the system pressure gauge reads 2756 kPa
(400 psi).
Unit 3 -2- Hydraulic Fundamentals
Instructor Copy Lab 3.7.2

LAB 3.7.2: COMPARE THE OPERATING FORCES OF TWO CYLINDERS (continued)

12. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
13. Turn OFF the training unit. Reverse the hoses as in No. 2.
14. Turn ON the training unit and extend the cylinder.
15. Turn OFF the training unit
16. Remove the load spring from the 1 1/16" bore cylinder and install the load spring on the 1 1/2"
bore cylinder (Extend the cylinder if needed).
17. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
18. Turn ON the training unit.
19. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
20. Turn OFF the training unit.
21. Calculate the approximate retraction force of the two cylinders on the training unit. Disregard
rod areas for these calculation.

BORE SIZE STARTING ENDING RETRACTION

SPRING SPRING
LENGTH LENGTH

11.3 cm 9.7 cm
1 1/16" (4.4 in) (3.8 in) 1.6 cm

11.3 cm 8.3 cm
1 1/2" (4.4 in) (7.5 in) 3.0 cm
Fig. 3.7.10

Calculate the areas and the forces.

Multiply the area times the pressure (PSI) to obtain force.
1-1/16" Bore: Area = 0.885 in.2
Force = 354 lb.

1-1/2" Bore: Area = 1.766 in.2

Force = 706 lb.
Unit 3 -1- Hydraulic Fundamentals
Student Copy Lab 3.7.2

Student Copy: Lab 3.7.2

Name _________________________

NUT AND
WASHERS
CYLINDER
SYSTEM
RELIEF 2
PRESSURE SPRING
VALVE
GAUGE
WASHER

1 1

SYSTEM
RELIEF
2
VALVE

BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 3.7.9

LAB 3.7.2: COMPARE THE OPERATING FORCES OF TWO CYLINDERS

Purpose
To compare the operating forces of two cylinders of known bore sizes.
Material Needed
Basic Hydraulic Training Unit
Procedure
1. Build the circuit shown in Figure 3.7.9.
2. Reverse the hoses to the cylinder (rod end hose to the head end and the head end hose to the
rod end).
3. Turn the cylinder relief valve fully counter-clockwise.
4. Adjust the system pressure to 5856 kPa (850 psi).
5. Turn ON the training unit.
6. Using the cylinder relief valve, increase the system pressure enough to fully extend the rod on
the 1 1/16" bore cylinder and install the load spring.
7. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
8 Turn OFF the training unit.
9. Connect the cylinder hoses as shown in Figure 3.7.9.
10. Turn ON the machine.
11. Turn the cylinder relief valve screw clockwise until the system pressure gauge reads 2756 kPa
(400 psi).
Unit 3 -2- Hydraulic Fundamentals
Student Copy Lab 3.7.2

LAB 3.7.2: OPERATING FORCES OF TWO CYLINDERS (continued)

12. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
13. Turn OFF the training unit. Reverse the hoses as in No. 2.
14. Turn ON the training unit and extend the cylinder.
15. Turn OFF the training unit
16. Remove the load spring from the 1 1/16" bore cylinder and install the load spring on the 1 1/2"
bore cylinder (Extend the cylinder if needed).
17. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
18. Turn ON the training unit.
19. Measure the length of the load spring and record the measurement on the chart in Figure
3.7.10.
20. Calculate the approximate retraction force of the two cylinders on the training unit. Disregard
rod areas for these calculation.
21. Turn OFF the training unit.

BORE SIZE STARTING ENDING RETRACTION

SPRING SPRING
LENGTH LENGTH

1 1/16"

1 1/2"

Fig. 3.7.10

Find the area of the cylinder.

Unit 3 -1- Hydraulic Fundamentals
Instructor Copy Quiz 3.7.1

Instructor Copy: Quiz 3.7.1

Name _________________________
CYLINDERS QUIZ

Fill in the blanks or circle the best answer.

1. Cylinders are basically linear actuators

2. Cylinder outputs are straight line motion or force.

3. The two cylinder ends are referred to as the rod end and the head end.

4. In a single acting cylinder, oil pressure acts upon the piston to extend the rod and lift the load.

5. The double acting cylinder is used on systems where the cylinder is required to do work in
both directions.

6. The bore size of the cylinder refers to the inside diameter of the cylinder.

7. The effective area of the rod end is smaller than the effective area of the head end.

8. The cylinder retraction is slightly faster than the cylinder extension for a given flow rate.

9. The piston seal is used between the piston and the cylinder wall.

10. The Head or ('O' ring) seal prevents oil escaping between the rod gland and the cylinder wall.

11. The wiper seal prevents dirt and grit from entering the cylinder as the cylinder rod is retracted.

12. When the moving cylinder runs into a dead end the concussion is called shock loading.

13. The snubber (damper) restricts return oil and causes a cushioning effect in the cylinder.

14. Identify the cylinder seals.

B
A
LOAD

D
A. Piston Seal C. Wiper Seal

B. Head Seal D. Rod Seal

Unit 3 -1- Hydraulic Fundamentals
Student Copy Quiz 3.7.1

Student Copy: Quiz 3.7.1

Name _________________________
CYLINDERS QUIZ

Fill in the blanks or circle the best answer.

1. Cylinders are basically actuators

2. Cylinder outputs are motion or force.

3. The two cylinder ends are referred to as the and the .

4. In a single acting cylinder, oil pressure acts upon the to extend the rod and lift the load.

5. The double acting cylinder is used on systems where the cylinder is required to do work in
.

6. The bore size of the cylinder refers to the .

7. The of the rod end is smaller than the of the head end.

8. The cylinder is slightly faster than the cylinder for a given flow rate.

9. The is used between the and the cylinder wall.

10. The prevents oil escaping between the rod gland and the cylinder wall.

11. The prevents dirt and grit from entering the cylinder as the cylinder rod is
retracted.

12. When the moving cylinder runs into a dead end the concussion is called .

13 The restricts return oil and causes a cushioning effect in the cylinder.

B
A
LOAD

14. Identify the cylinder seals.

A. C.

B. D.