Hydraulic Design Upload (Sem1 2023 New)

12/17/2023
Hydraulic system
Tran Hai Nam
namth@hcmut.edu.vn
2023
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In The Beginning…
In the 17th century Pascal developed the law of confined fluids.
Pascal’s Law, simply stated, says:
“Pressure applied on a confined fluid

is transmitted undiminished in all directions,
and acts with equal force on equal areas,
and at right angles to them”.
Pascal’s Law
1. The bottle is filled
with a liquid, which
is not compressible,
for example, 4. If the bottom has an
hydraulic oil. area of 20 square
inches and each
2. A 10 lb. of force square inch is pushed
applied to a stopper on by the 10 lb. of
with a surface area force, the entire
of one square inch. bottom receives a
3. Results in 10 lb. of 200 lb. push.
force on every
square inch
(pressure) of the 10 lbs. x 20 sq. in.= 200 ?
container wall.
“Pressure applied on a confined fluid is transmitted undiminished in all directions,

and acts with equal force on equal areas, and at right angles to them”.
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Introduction to Hydraulics
Pascal’s Law: A Closer Look
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Pascal’s Law Explained Using A Fulcrum
Explaining Piston Displacement
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Force
The relationship of force, pressure, and area is as follows:
F=PxA
where-
• F = force, in pounds
• P = pressure, in psi
• A = area, in square inches
Example: Figure shows
a pressure of 50 psi being applied to

an area of 100 square inches.
The total force on the area is F = P x A
F = 50 (psi) x 100 (sq in) = 5,000 (pounds)
Solving For Pressure F

F = P x A solves for Force.
P= Solves for Pressure
Shifting the same equation will A F = Force
P = Pressure
allow you to solve for Force or
Pressure. A = Area in sq. inches
F = P x A Solves Force
P = F/A Solves Pressure
A= F/P Solves Area
R
o
d
Piston
Cylinder
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How many
cubic inches
of oil is in
one US gallon?
231 cubic inches
Energy transfer into and out

of a hydraulic system
Energy transfer into and out of a

hydraulic system includes energy
loss (in the form of heat) due to
frictional fluid flow through pipes,
valves, and fittings
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Example of hydraulic circuit with symbols
1. Cylinder
2. Pressure Relief Valve
3. 4/3 Directional Valve
4. Pressure Gauge
5. Pressure Relief Valve
6. Hydraulic Pump
7. Hydraulic Fuse
8. Check Valve
9. Tank (Reservoir)
10. Pilot-Operated Check Valve
Pumping action of a simple piston pump
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Rotary pump
Detailed features of an external gear pump. (Courtesy of Webster Electric Company, Inc., subsidiary of STA-RITE Industries, Inc., Racine, Wisconsin.)
Oil has Weight
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Weight of Fluid
Weight of Air
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Using the Weight of Oil to help feed a Pump
Lifting Oil
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Air Intake From Loose Connections
Charged from oil above Vacuum required to feed pump
• The drawing on the left provides some charged pressure, while the drawing
on the right requires vacuum.
• In either case, if there is any leaks on the suction hose leading to the pump,
the leak could draw air into the system.
• Air in the system can cause pump failure due to cavitation (air in system).
When There Is No Movement Of Oil

Then The Pressure Is The Same
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How Pressure Is Lost Through An Orifice
Larger Orifices Steal Less Pressure Or Work
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Flow Blocked, Pressure Equalized!
A Review Of Flow
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Fast Moving Oil May Become Turbulent
Slow Moving Oil
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Basic Symbols of Hydraulics
Basic Symbols: Lines
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Circle, Semi-Circle
Square, Rectangle, Diamond
Square, Rectangle
squares - control components
Diamond
diamond – Condition apparatus (filter,

separator, lubricator, heat exchanger
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Miscellaneous Symbols
Spring
Restriction
Restriction
Pump Symbols
Fixed Displacement Hydraulic

Pump-unidirectional (pumps only when
rotated in one direction. Will not pump if turned backwards)
Variable Displacement
Hydraulic Pump-bidirectional
(pumps when rotated in both forward and reverse rotation)
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Motors-Fixed Displacement
Unidirectional
(rotates only one direction)
Bidirectional (rotates in both directions)
Reading Lines
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Reading Symbols For Pumps And Motors
Reading Symbols For Cylinders
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Symbols For Pilot Operated Relief Valves
Understanding Valves
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Understanding Valves
Understanding Reservoir Lines And Symbols
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Spool Valve Positions- Finite & Transition
in/out Stop Reverse Directions
Hand Operated
(could be electric
solenoid or even air
operated)
Example of hydraulic circuit with symbols

Continuous lines ?
Dash lines?
Circle ?
…
1. Cylinder 6. Hydraulic Pump

2. Pressure Relief Valve 7. Hydraulic Fuse
3. 4/3 Directional Valve 8. Check Valve
4. Pressure Gauge 9. Tank (Reservoir)
5. Pressure Relief Valve 10. Pilot-Operated Check Valve
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Hydraulic Pumps / Motors
Hydraulic Power Units
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Learning Objectives
1. Distinguish between positive displacement and dynamic (nonpositive displacement) pumps.
2. Describe the pumping action of pumps.
3. Explain the operation of gear, vane, and piston pumps.
4. Determine the flow rate delivered by positive displacement pumps.
5. Differentiate between axial and radial piston pumps.
6. Understand the difference between fixed displacement and variable displacement pumps.
7. Explain the operation of pressure-compensated pumps.
8. Distinguish between bent-axis-type piston pumps and the swash plate design.
9. Differentiate between internal and external gear pumps.
10. Evaluate the performance of pumps by determining the volumetric, mechanical, and overall efficiencies.
11. Explain the phenomenon of pump cavitation and identify ways to eliminate its occurrence.
12. Compare the various performance factors of gear, vane, and piston pumps.
13. Understand the significance of sound intensity levels in decibels.
14. Explain the causes of pump noise and identify ways to reduce noise levels.
15. Describe the sequence of operations used to select a pump for a given application.
Introduction
There are two broad classifications of pumps
1. Dynamic (nonpositive displacement) pumps (Bơm
động lực)
• This type is generally used for low-pressure, high-
volume flow applications.
• Normally their maximum pressure capacity is limited
to 250–300 psi.
2. Positive displacement pumps (Bơm thể tích)

• This type is universally used for fluid power systems.
• A positive displacement pump ejects a fixed amount
of fluid into the hydraulic system per revolution of
pump shaft rotation.
• High-pressure capability (up to 12,000 psi)
• A pump is capable of overcoming the pressure
resulting from
 the mechanical loads on the system
 as well as the resistance to flow due to friction.
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Introduction
1. Dynamic (nonpositive displacement) pumps.
• Low-pressure, high-volume flow
applications.
• Maximum pressure capacity is
normally limited to 250–300 psi.
• Primarily used for transporting
fluids from one location to another.
• Smooth continuous flow.
• There is no need for a pressure relief valve
to prevent pump damage
The output flow rate is reduced

as resistance to flow is increased.
Introduction
• The tips of the impeller blades merely
• Low-pressure, high-volume flow slosh through the fluid, and the rotational
applications (because of clearance between speed maintains a fluid pressure
the rotating and stationary elements).
corresponding to the centrifugal force
• The large clearance space does not permit established.
a suction pressure to occur at the inlet • There is no positive internal seal against
port when the pump is first turned on. leakage (this is the reason that the
• Priming is required (priming is the prefilling centrifugal pump is not forced to produce
of the pump housing and inlet pipe with fluid so
that the pump can initially draw in the fluid and
flow against demand).
pump it efficiently). • There is no need for a pressure relief
valve to prevent pump damage
• The rotating impeller picks up the fluid at • The maximum pressure is called the
the center of the impeller through inlet. shutoff head (because an external circuit valve
• The fluid is moved radially outward is closed, which shuts off the flow).
through the outlet discharge port of the • As the external resistance decreases due to
housing by the centrifugal force (as the the valve being opened, the flow increases
fluid rotates with the impeller). at the expense of reduced pressure.
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Introduction
• The two most common types of dynamic pumps:
 the centrifugal (impeller) pumps
 the axial (propeller) pumps
Introduction
2. Positive displacement pumps
• Universally used for fluid power systems.
• Ejects a fixed amount of fluid into the hydraulic
system per revolution of pump shaft rotation.
• Overcoming the pressure resulting from
 the mechanical loads on the system
 the resistance to flow due to friction.
These pumps have the following advantages
over nonpositive displacement pumps:
a. High-pressure capability (up to 12,000 psi)
b. Small, compact size
c. High volumetric efficiency
d. Small changes in efficiency throughout the
design pressure range
e. Great flexibility of performance (can operate
over a wide range of pressure requirements
and speed ranges)
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Introduction
2. Positive displacement pumps
• Although these pumps come in a wide variety of different designs, there are essentially
three basic types:
1. Gear pumps (fixed displacement only by geometrical necessity)
a. External gear pumps
b. Internal gear pumps
c. Lobe pumps
d. Screw pumps
2. Vane pumps
a. Unbalanced vane pumps (fixed or variable displacement)
b. Balanced vane pumps (fixed displacement only)
3. Piston pumps (fixed or variable displacement)

a. Axial design
b. Radial design
GEAR PUMPS - External Gear Pump

Volumetric Displacement and Theoretical Flow Rate
The volumetric displacement
can be represented by Eq.
Do outside diameter of gear teeth (in, m)
Di inside diameter of gear teeth (in, m)
L width of gear teeth (in, m)
The theoretical flow rate (in English units)

is determined next:
Since 1 gal 231 in3, we have
Using Metric Units, we have
Volumetric Efficiency
Internal leakage, called pump slippage, is identified VD displacement volume of pump (in3/rev, m3/rev)
N rpm of pump
by the term volumetric efficiency, ηυ QT theoretical pump flow rate QA actual pump flow rate
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Volumetric Displacement and Theoretical Flow Rate Ex.1.
The volumetric displacement A gear pump has
can be represented by Eq. a 3-in outside diameter,
a 2-in inside diameter, and
Di inside diameter of gear teeth (in, m) a 1-in width.
L width of gear teeth (in, m) If the actual pump flow at 1800 rpm
The theoretical flow rate (in English units) and rated pressure is 28 gpm,
is determined next: what is the volumetric efficiency?
Solution Find the displacement volume

Find the theoretical flow rate

The volumetric efficiency is then found
N rpm of pump

Volumetric Displacement and Theoretical Flow Rate Ex.2.
The volumetric displacement A gear pump has
can be represented by Eq. a 75-mm outside diameter,
a 50-mm inside diameter, and
Di inside diameter of gear teeth (in, m) a 25-mm width.
L width of gear teeth (in, m) If the volumetric efficiency is 90% at
The theoretical flow rate (in English units) rated pressure and the pump speed is
is determined next: 1000 rpm, what is the corresponding
actual flow rate?
Solution The volume displacement is

Since 1 L = 0.001 m3, VD 0.0614 L

Find the actual flow rate
Since 1 L = 0.001 m3, we have

N rpm of pump
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GEAR PUMPS - Internal Gear Pump
GEAR PUMPS - Lobe Pump

• This pump operates in similar to the external gear
pump.
• Both lobes are driven externally so that they do not

actually contact each other (unlike the external gear
pump) that are quieter than other types of gear
pumps.
• Due to the smaller number of mating elements, the

lobe pump output will have a somewhat greater
amount of pulsation, although its volumetric
displacement is generally greater than that for other
types of gear pumps.
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GEAR PUMPS - Gerotor Pump

• Operates very much like the internal gear
pump.
• The inner gear rotor (Gerotor element) is
power-driven and draws the outer gear
rotor around as they mesh together.
• This forms inlet and discharge pumping
• chambers between the rotor lobes.
• The tips of the inner and outer rotors
make contact to seal the pumping
chambers from each other.
• The inner gear has one tooth less than
the outer gear, and the volumetric
displacement is determined by the space
formed by the extra tooth in the outer
rotor.
GEAR PUMPS - Screw Pump

• Screw Pump is an axial flow positive displacement unit.
• Three precision ground screws, meshing within a closefitting
housing, deliver non-pulsating flow quietly and efficiently.
• The two symmetrically opposed idler rotors act as rotating
seals, confining the fluid in a succession of closures or stages.
The idler rotors are in rolling contact with the central power
rotor and are free to float in their respective housing bores
on a hydrodynamic oil film.
There are no radial

bending loads.
Axial hydraulic forces on
the rotor set are balanced,
eliminating any need for
thrust bearings.
High-pressure designs are
available for 3500-psi
operation with output
flow rates up to 88 gpm.
a cutaway view of an actual screw pump.
It is rated at 500 psi and can deliver up to 123 gpm.
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VANE PUMPS
• There is an eccentricity between
o the centerline of the rotor and
o the centerline of the cam ring.
• If the eccentricity is zero, there will be no flow.
The maximum possible eccentricity:
This maximum value of eccentricity produces

a maximum volumetric displacement:
We have the difference between two squared

terms yields DC diameter of cam ring (in, m)
DR diameter of rotor (in, m)
L width of rotor (in, m)
VD pump volumetric displacement (in3, m3)
Substituting the expression for emax yields e eccentricity (in, m)
emax maximum possible eccentricity (in, m)
VDmax maximum possible volumetric
The actual volumetric displacement occurs when emax = e: displacement (in3, m3)

VANE PUMPS
with Variable displacement, pressure-compensated vane pump
• Some vane pumps have provisions for mechanically varying the eccentricity.
• Such a design is called a variable displacement pump.
• A handwheel or a pressure compensator can be used to move the cam ring to change the
eccentricity.
• The direction of flow through the pump can be reversed by movement of the cam ring on
either side of center.

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VANE PUMPS
with Variable displacement, pressure-compensated vane pump
• System pressure acts directly on the cam ring via a hydraulic piston on the right side (not shown). It forces the
cam ring against the compensator spring-loaded piston on the left side of the cam ring.
• If the discharge pressure is large enough, it overcomes the compensator spring force and shifts the cam ring to
the left. This reduces the eccentricity (which is maximum when discharge pressure is zero).
• As the discharge pressure continues to increase, zero eccentricity is finally achieved, and the pump flow
becomes zero.
• Such a pump basically has its own protection against excessive pressure buildup.
• When the pressure reaches a value called pcutoff, the compensator spring force equals the hydraulic piston force.
• As the pressure continues to increase, the compensator spring is compressed until zero eccentricity is achieved.
• The maximum pressure achieved is called pdeadhead, at which point the pump is protected because it produces no
more flow. As a result, there is no power wasted and fluid heating is reduced.
Cutaway view of
Balanced Vane Pump

balanced vane pump
• A balanced vane pump is one that has two intake and

two outlet ports diametrically opposite each other.
• Thus, pressure ports are opposite each other, and a
complete hydraulic balance is achieved.
• One disadvantage of a balanced vane pump is that it
cannot be designed as a variable displacement unit.
• Instead of having a circular cam ring, a balanced design vane pump
has an elliptical housing, which forms two separate pumping
chambers on opposite sides of the rotor.
• This eliminates the bearing side loads
and thus permits higher operating
pressures.
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Vane Pump EXAMPLE

EXAMPLE Solution
• A vane pump is to have a volumetric displacement of 5 in3.
• It has a rotor diameter of 2 in, a cam ring diameter of 3 in,
and a vane width of 2 in. Solution
• What must be the eccentricity?
EXAMPLE
• A vane pump has a rotor diameter of 50 mm, a cam
ring diameter of 75 mm, and a vane width of 50 mm.
• If the eccentricity is 8 mm, determine the volumetric
displacement. Solution
The fixed displacement pump produces 20 gpm at 1200 psi
EXAMPLE when the cylinder is fully extended (0.7 gpm leakage flow
• A fixed displacement vane pump delivers (1000 psi oil through the cylinder and 19.3 gpm through the relief valve)
to an extending hydraulic cylinder) at 20 gpm.
• When the cylinder is fully extended, oil leaks past its
piston at a rate of 0.7 gpm. The pressure relief valve
setting is 1200 psi. A pressure-compensated pump would produce only 0.7 gpm
at 1200 psi when the cylinder is fully extended. For this case
• If a pressure compensated vane pump were used it
would reduce pump flow from 20 gpm to 0.7 gpm
when the cylinder is fully extended to provide the
leakage flow at the pressure relief valve setting of
Hence, the hydraulic horsepower saved 14.0 0.49 13.51 hp.
1200 psi.
This horsepower savings occurs only while the cylinder is fully
• How much hydraulic horsepower would be saved by extended because either pump would deliver 1000 psi oil at
using the pressure-compensated pump? 20 gpm while the cylinder is extending
How a Piston
Pump Works
https://theconstructor.org/practical-guide/reciprocating-pump-components-working-uses/2914/
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How a Piston
Pump Works
How A Piston
Motor Works
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Hydraulic Circuit
Design and Analysis
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Definition of Hydraulic Circuits

• A hydraulic circuit
• is a group of components such as
• pumps,
• actuators,
• control valves, and
• conductors
• will perform a useful task.
• are developed using graphic symbols for all components
• Three important considerations when analyzing or designing

hydraulic circuits:
1. Safety of operation
2. Performance of desired function
3. Efficiency of operation
Appendix G gives a table of symbols that conforms to the American National Standards
Institute (ANSI) specifications
Energy and Power in Hydraulic Systems
Figure 3-1. Block diagram of hydraulic

system showing major components along
with energy input and output terms.
where
ME mechanical energy,
HE heat energy.
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REVIEW OF MECHANICS
When an object travels a known
Velocity and Acceleration distance and the time taken to do
this is also known, then the velocity
• Velocity is often used in place of speed. can be calculated as follows:
• They are different.
 Speed is
o the rate at which some object is travelling
o measured in metres/second (m/s)
o no indication of the direction of travel.
 Velocity
o is speed plus direction.
o defines movement in a particular direction
o is also measured in metres/second (m/s).
• In hydraulics, term velocity is used instead of speed
to know which direction oil is moving.

REVIEW OF MECHANICS
Velocity and Acceleration
• Acceleration describes change in velocity.

• When an object's velocity is increasing then it is accelerating; when it is slowing down it
is decelerating.
• Acceleration ‘a’ is measured in metres/second/ second (m/s2).
If the initial and final velocities are known as well as the time taken for the velocity
to change then the acceleration can be calculated as follows:
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REVIEW OF MECHANICS
EXAMPLE: CALCULATING VELOCITY AND ACCELERATION

REVIEW OF MECHANICS
Forces
• Forces are essential to the production of work.
• No motion can be generated and hence no power can be transmitted without the
application of some force.
• It was in the late seventeenth century when Sir Isaac Newton formulated the three laws
of motion dealing with the effect a force has on a body.
• One way of describing force is to say that a force causes movement
Sir Isaac Newton (1642–1728)
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REVIEW OF MECHANICS
Law 1: forces cause movement

Law 2: forces cause objects to accelerate
Law 3: for every force there is always an equal and opposite force
Law 1. A force is required to change the

motion of a body.
Law 2. If a body is acted on by a force, the

body will have an acceleration proportional
to the magnitude of the force and inverse to
the mass of the body.
force (N) = mass (kg) x acceleration (m/s2)
Law 3. If one body exerts a force on a

second body, the second body must exert an
equal but opposite force on the first body.

REVIEW OF MECHANICS Linear Motion
EXAMPLE: CALCULATING FORCE USING NEWTON'S SECOND LAW
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Work, energy and power
Let’s assume that a force acts on a body and moves the body through a specified distance
in the direction of the applied force.
Work is done when a force produces movement.
Then, by definition, work has been done on the body.
The amount of this work equals the product of the force and distance where both the
force and distance are measured in the same direction:

Work, energy and power
The amount of energy needed to do a job is determined by the amount of work to be done.
Energy enables useful work to be done.
Energy, like work, is measured in Newton-metres (Nm) but the more conventional
measurement of energy is watt-seconds (Ws). Some scientists measure energy in joules (J).
Joule is the English physicist, James Joule (1818–1889)
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Power is often confused with the term energy.
They are related but they have different meanings.
Energy is the capacity to do useful work
power is the rate at which the energy is used

This leads us to a discussion of power, which
is defined as the rate of doing work
or expending energy.
Thus, power equals work divided by time:
Power is a measure of how fast work is done and (in the English system of units) is usually
measured in units of horsepower (hp). By definition, 1 hp equals 550 ft . lb/s or 33,000 ft .
lb/min. Thus, we have
The unit of horsepower was created by James Watt at the end of the nineteenth century,
when he attempted to compare the rate of doing work by a horse in comparison with a steam engine.
During a test he showed that a horse could raise a 150-lb weight (using a block-and-tackle) at an average velocity of
3.67 ft/s.
This rate of doing work equals 150 lb x 3.67 ft/s or 550 ft lb/s, which he defined as 1 horsepower.
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Momentum
Applying a force to a mass causes it to accelerate (Newton's second law) and the effect of
this is to cause a change in velocity.
This means there is a link between mass and velocity and this is called momentum.

Momentum
Momentum change produces the forces.
It is called the impulse
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Momentum
Momentum change produces the forces.

REVIEW OF MECHANICS • There are two ways of expressing density:
 Mass density
Density
 Weight density.
• Mass density is determined by dividing For example, the mass density of

the mass of some object by its volume.  air is 1.29 kg/m3,
• Mass density is usually denoted by the  steel is 7800 kg/m3
Greek letter ρ (rho)  gold is 19 300 kg/m3
 water is 1000 kg/m3
For water:
• Density can also be written in terms Weight density = 1000 kg/m3 x 9.8 m/s2
of weight as well as mass = 9810 N/m3 (or 9.81 kN/m3)
= 10 kN/m3 (approximately)
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REVIEW OF MECHANICS • SG is the ratio of the density of a material or fluid to
that of some standard density – usually water.
Relative density or specific gravity
• SG can be written both in terms of the mass density
and the weight density
The mass density of
 air is 1.29 kg/m3,
 steel is 7800 kg/m3
 gold is 19 300 kg/m3
The mass density of mercury is 13.6 times greater than that of water

REVIEW OF MECHANICS • SG is the ratio of the density of a material or fluid to
that of some standard density – usually water.
Relative density or specific gravity
• SG can be written both in terms of the mass density
and the weight density
The mass density of
 air is 1.29 kg/m3,
 steel is 7800 kg/m3
 gold is 19 300 kg/m3
The mass density of mercury is 13.6 times

greater than that of water
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REVIEW OF MECHANICS • This is the friction force which exists inside a fluid as
it flows.
Viscosity (dynamic viscosity) • This internal friction between the layers of fluid is
known as the viscosity.
• Some fluids, such as water, have a low viscosity and
this means the friction between the layers of fluid is
low and its influence is not so evident when water is
flowing.
• In contrast engine oils have a much higher viscosity
and they seem to flow more slowly.
• This is because the internal friction is much greater.
• The forces of viscosity are usually very small relative
to other forces involved.
• When forces of viscosity are ignored the fluid is
described as an ideal fluid.
• Most common fluids conform to this relationship
and are still known today as Newtonian fluids.
• Viscosity is usually denoted by the Greek letter (mu)
• Viscosity decreases with increasing temperature.

REVIEW OF MECHANICS • In many hydraulic calculations viscosity and mass
density go together and so they are often combined
Kinematic viscosity into a term known as the kinematic viscosity.
• It is denoted by the Greek letter (nu)
• Sometimes kinematic viscosity is measured in

Stokes
• George Stokes who helped to develop a fuller
understanding of the role of viscosity in fluids.
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REVIEW OF MECHANICS
Surface tension
• An ordinary steel sewing needle can be made to float on water if it is placed there very
carefully.
• A close examination of the water surface around the needle shows that it appears to be
sitting in a slight depression and the water behaves as if it is covered with an elastic skin.
• This property is known as surface tension.
• The force of surface tension is very small and is normally expressed in terms of force per
unit length.
• This force is ignored in most hydraulic calculations but in hydraulic modelling, where
small-scale models are constructed in a laboratory to try and work out forces and flows in
large, complex problems, surface tension may influence the outcome because of the
small water depths and flows involved.

REVIEW OF MECHANICS - EXAMPLE 3-1 Linear Motion
A person exerts a 30-lb force to move a hand truck 100ft in 60s.
a. How much work is done?
b. What is the power delivered by the person?
a. How much work is done?
b. What is the power delivered by the person?
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REVIEW OF MECHANICS Angular Motion
Just as in the case of linear motion, angular motion is caused by the application of a force.
Consider, for example, a force F applied to a wrench to tighten a bolt as shown in Figure.
The force F has a moment arm R relative to the center of the bolt.
Thus, the force F creates a torque T about the center of the bolt.
It is the torque T that causes the wrench to rotate the bolt through a given angle until it is
tightened. Note that the moment arm is measured from the center of the bolt (center of
rotation) perpendicularly to the line of action of the force.

A second example of angular motion is
illustrated in Figure. A force F applied to
a flat belt wrapped around the periphery
of a circular disk mounted on a shaft. The shaft is mounted
in bearings so that it
The force F creates a torque T whose
can rotate as it drives
magnitude equals the product of the
the connecting shaft
force F and its moment arm R that
of a pump.
equals the radius of the disk.
The resulting torque causes the disk and

thus the connecting shaft to rotate at some
angular speed measured in units of
revolutions per minute (rpm).
The resulting torque is
clockwise because it rotates
the shaft clockwise as shown.
As the shaft rotates and overcomes the load resistance of the

pump, work is done and power is transmitted to the pump.
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is used to calculate the horsepower

the value of 63,000 for the
delivered by a prime mover (such as an constant in the denominator
electric motor) to drive a pump or by a is valid only when the torque
hydraulic motor to drive an external load. T has units of in lb and the
rotational speed N has units
of rpm.
This is transmitted by torque in a

rotating shaft, it is called torque
Efficiency horsepower.
It is also commonly called brake
horsepower (BHP) because a brake is
a mechanical device used to measure
the amount of horsepower
Efficiency is defined as output power divided by transmitted by a torque-driven
input power. Mathematically we have rotating shaft.
The power difference (input power – output power)
represents loss power

REVIEW OF MECHANICS - EXAMPLE 3-2 Angular Motion
How much torque is delivered by a 2-hp,

1800-rpm hydraulic motor?
the value of 63,000 for the constant in the denominator is valid

only when the torque T (in.lb) and the rotational speed N (rpm).
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REVIEW OF MECHANICS - EXAMPLE 3-3 Angular Motion
An elevator raises a 3000-lb load
through a distance of 50 ft in 10 s.
If the efficiency of the entire system is
80% (0.80 in decimal fraction form for
use in equations),
How much input horsepower is required
by the elevator hoist motor?
the value of 63,000 for the constant in the denominator is valid

only when the torque T (in.lb) and the rotational speed N (rpm).

MULTIPLICATION OF FORCE (PASCAL’S LAW) Analysis of Simple Hydraulic Jack
Pressure applied to a confined fluid is

transmitted undiminished in all directions
throughout the fluid and acts perpendicular
to the surfaces in contact with the fluid.
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MULTIPLICATION OF FORCE (PASCAL’S LAW)
Pressure applied to a confined fluid is the volume of a cylinder
transmitted undiminished in all directions
throughout the fluid and acts perpendicular
to the surfaces in contact with the fluid.
Analysis of Simple Hydraulic Jack
The force multiplication ratio The piston

equals the piston area ratio stroke ratio

MULTIPLICATION OF FORCE (PASCAL’S LAW) - EXAMPLE 3-4
the volume of a cylinder
Determine each
of the following.
Analysis of Simple Hydraulic Jack

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MULTIPLICATION OF FORCE (PASCAL’S LAW) - EXAMPLE 3-5 Hydraulic Jack
Hand-operated hydraulic jack


• An operator makes one complete
Hydraulic Jack
cycle per second interval using the
hydraulic jack of Figure 3-8.
• Each complete cycle consists of two

pump cylinder strokes (intake and
power).
• The pump cylinder has a 1-in-

diameter piston and the load
cylinder has a 3.25-in-diameter
piston.
• If the average hand force is 25 lbs

during the power stroke,
a. How much load can be lifted?

b. How many cycles are required to lift the load 10 in
assuming no oil leakage? The pump piston has a 2-in stroke.
c. What is the output HP assuming 100% efficiency?
d. What is the output HP assuming 80% efficiency?
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Hydraulic Jack
a. How much load can be lifted?
First determine the force acting on

the rod of the pump cylinder due to
the mechanical advantage of the
input handle:
Next, calculate the pump cylinder

discharge pressure p:
Per Pascal’s law this is also the same pressure acting on the load piston.
We can now calculate the load-carrying capacity:

Hydraulic Jack
b. How many cycles are required to lift
the load 10 in assuming no oil leakage?
The pump piston has a 2-in stroke.
To find the load displacement,

assume the oil to be in-compressible.
Therefore, the total volume of oil
ejected from the pump cylinder equals
the volume of oil displacing the load cylinder:
Substituting, we have
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Hydraulic Jack
c. What is the output HP assuming 100%
efficiency?
d. What is the output HP assuming 80% efficiency?
One HP means that the 550 pounds of force keep the system to move 1 feet in 1 second
Thinking about what is happened with the speed of load when reducing its weight?

MULTIPLICATION OF FORCE (PASCAL’S LAW) Air-to-Hydraulic Pressure Booster
Manufacturing application of air-to-hydraulic pressure booster
Air-to-hydraulic pressure boosters are

available in a wide range of pressure ratios
and can provide hydraulic pressures up to
15,000 psi using 100-psi shop air.
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A pressure booster used to drive Air-to-Hydraulic Pressure Booster
a load F via a hydraulic cylinder.
The following data are given
Find the load-carrying capacity F

of the system.

A pressure booster used to drive a load F Air-to-Hydraulic Pressure Booster
via a hydraulic cylinder. The following data
are given
First, find the booster discharge

pressure p2:
To produce this force without the booster

would require a 500-in2-area load piston
Per Pascal’s law, p3 p2 2000 psi: (diameter 25.2 in), assuming 100-psi air
pressure.
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CONSERVATION OF ENERGY
Potential energy due to elevation (EPE)
• A chunk of fluid of weight W(lb) at an elevation Z
with respect to a reference plane.
• The weight has potential energy (EPE) relative to
the reference plane because work would have to
be done on the fluid to lift it through a distance Z
Potential energy due to pressure (PPE)
• If the W(lb) of fluid in Figure possesses a pressure p,
it contains pressure energy as represented by PPE
• Where, γ is the specific weight of the fluid
Kinetic energy (KE)
• If the W(lb) of fluid in Figure is moving with a
velocity υ, it contains kinetic energy, which can be
found by KE
• where g acceleration of gravity
The total energy (ET) possessed by the W-lb chunk of fluid remains constant
(unless energy is added to the fluid via pumps or removed from the fluid via hydraulic
motors or friction) as the W-lb chunk flows through a pipeline of a hydraulic system.
THE CONTINUITY EQUATION Continuity of flow

Use of Weight Flow Rate
The continuity equation states that for
steady flow in a pipeline, the weight flow
rate w (weight of fluid passing a given
station per unit time) is the same for all
locations of the pipe.
The continuity equation states that if no fluid is added or withdrawn from the pipeline
between stations 1 and 2, then the weight flow rate at stations 1 and 2 must be equal.
Use of Volume Flow Rate

If the fluid is a liquid we can cancel out the specific weight
terms from the continuity equation. This is because a liquid
is essentially incompressible, and hence γ1 γ2.
The result is the continuity equation for hydraulic systems:
For hydraulic systems, the volume flow rate is also constant in a pipeline.
The smaller the pipe size, the greater the velocity, and vice versa.
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THE CONTINUITY EQUATION Continuity of flow

EXAMPLE 3-7
the following data are given:
Find:
a. The volume flow rate Q
b. The fluid velocity at station 2
HYDRAULIC POWER
Hydraulic Cylinder Example
Find the power delivered by a hydraulic fluid to
a load-driving device such as a hydraulic cylinder.
This power is called hydraulic power.
Allow us to answer the following three questions:
1. How do we determine how large a piston diameter is required for the cylinder?
2. What is the pump flow rate required to drive the cylinder through its stroke in a specified time?
3. How much hydraulic horsepower does the fluid deliver to the cylinder?
Note that
• The horsepower delivered by the fluid to the cylinder is called hydraulic horsepower (HHP).
• The horsepower delivered by the cylinder to the load is called output horsepower (OHP).
• The output horsepower delivered by the cylinder to the load equals the hydraulic horsepower minus
any horsepower loss due to friction and fluid leakage between the piston and bore of the cylinder.
• Output horsepower is always less than hydraulic horsepower due to friction and leakage losses.
• This is consistent with the fact that the efficiency of any component is always less than 100%.
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HYDRAULIC POWER
Answer to Question 1.
A pump
receives fluid on its inlet side at about atmospheric pressure (0 psig) and
discharges the fluid on the outlet side at some elevated sufficiently high pressure p.
This pressure p acts on the area of the piston A to produce the force required to
overcome the load:
Solving for the piston area A, we obtain
HYDRAULIC POWER
The volumetric displacement VD of the hydraulic cylinder
equals the fluid volume swept out by the piston traveling
through its stroke S:
If there is negligibly small leakage between the piston and
cylinder bore, the required pump volume flow rate Q equals
the volumetric displacement of the cylinder divided by the
time t required for the piston to travel through its stroke S.
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HYDRAULIC POWER
It has been established that energy equals force times distance:
Power is the rate of doing work
Since Q = Av, the final result is
HYDRAULIC POWER
• Observe the following power analogy among mechanical, electrical, and hydraulic systems.
• Conversion of power from input electrical to mechanical to hydraulic to output mechanical
in a hydraulic system.
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HYDRAULIC POWER
EXAMPLE 3-8
assuming a 100% efficient cylinder

(losses are negligibly small), the
hydraulic horsepower equals the
output horsepower
HYDRAULIC POWER
EXAMPLE 3-9
• Thus, a hydraulic horsepower of 14.8

must be delivered by the fluid to the
cylinder to produce an output
horsepower at 14.5 for driving the load.
• The efficiency of the cylinder is
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BERNOULLI’S EQUATION Z2 - Z1 = 20 ft.

υ1= 0 because the cross section
EXAMPLE 3-10 of an oil tank is large.
HL = 30 ft
p1 = 0 gage pressure
Since there is no hydraulic motor

between stations 1 and 2, Hm =0
265 obtained for p2 is a gage pressure since a gage pressure

value of zero was used in the energy equation for p1
Hydraulic Cylinders
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CYLINDER MOUNTINGS AND

MECHANICAL LINKAGES

MECHANICAL LINKAGES
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MECHANICAL LINKAGES

MECHANICAL LINKAGES
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MECHANICAL LINKAGES

MECHANICAL LINKAGES
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MECHANICAL LINKAGES

MECHANICAL LINKAGES
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MECHANICAL LINKAGES
the power developed equals the product of pressure and cylinder input volume
flow rate for both the extension and retraction strokes.

MECHANICAL LINKAGES
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MECHANICAL LINKAGES

MECHANICAL LINKAGES
EXAMPLE 6 -1
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MECHANICAL LINKAGES
EXAMPLE 6 -3 Find the cylinder force F required to lift the 6000-lb weight W of Example
6-2 along a direction which is 30° from the horizontal, as shown in Figure
6-8(a). The weight is moved at constant velocity.

MECHANICAL LINKAGES
EXAMPLE 6 - 4
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MECHANICAL LINKAGES
First-Class Lever System
At equilibrium, these two moments are equal in magnitude:

MECHANICAL LINKAGES
Second-Class Lever System
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MECHANICAL LINKAGES
Third-Class Lever System

MECHANICAL LINKAGES
EXAMPLE 6 - 5
Thus, as expected, the second-

class lever requires the smallest
cylinder force, whereas the
third-class lever requires the
largest cylinder force.
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HYDRAULIC CYLINDER CUSHIONS

EXAMPLE 6 - 6

MECHANICAL LINKAGES
EXAMPLE 6 - 6
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MECHANICAL LINKAGES
EXAMPLE 6 - 6
Thus, the hydraulic cylinder

must be designed to withstand
an operating pressure of 856 psi
rather than the pressure relief
valve setting of 750 psi.
Control of a Single-Acting Hydraulic Cylinder

Directional control valve (DCV)
• In the spring-offset mode, with a two-position, three-way,
• full pump flow goes to the tank manually actuated, spring-offset.
via the pressure relief valve.
• 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 manually
relief valve
actuated into its left envelope,
pump flow extends the cylinder.
• At full extension, pump flow goes through the relief valve.

• De-activation of the DCV allows the cylinder to
 retract as the DCV
 shifts into its spring-offset mode.
Appendix G gives a table of symbols that conforms to the American National Standards
Institute (ANSI) specifications
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Control of a Double-acting Hydraulic Cylinder

1. When the DCV is in its spring-centered
position (tandem design),
• the cylinder is hydraulically locked.
• the pump is unloaded back to the
Directional control valve (DCV) tank at essentially atmospheric
with a 3-position, 4-way, pressure.
manually actuated, spring-offset.
2. When the DCV 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 DCV from port B through port T.
• Note that the cylinder could not extend if this oil were
not allowed to leave the rod end of the cylinder.
3. When the DCV is de-activated,

• the spring-centered envelope prevails,
• and the cylinder is once again hydraulically locked.
Control of a Double-acting Hydraulic Cylinder
4. When DCV 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.
5. 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 de-activated.
In any event, the system is protected from

any cylinder overloads by using a relief valve.
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A regenerative circuit is used to

Regenerative Cylinder Circuit speed up the extending speed of a
double-acting hydraulic cylinder.
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 blank end of the cylinder.
In the center position mode of Directional control valve (DCV)

• Base port is blocked
• Rod port is also blocked because of the locked state of cylinder
• The fluid drains back to the tank through the relief valve after
archived the setting value.
In the left envelope mode of DCV In the right envelope mode of DCV
(the cylinder extends) (the re-traction stroke)
• Fluid from the pump • Fluid from the pump
 Enters the base port through the DCV  bypasses the DCV
 Hope to enters the rod and port  and enters the rod end of the cylinder
• The same pressure in both cylinder’ chambers • Fluid in the blank end of cylinder
 Decides the direction of fluid flow from the  through the DCV via base port
end rod chamber back to pump outlet.  drains back to the tank.
A common method used to block a valve port is to simply screw a threaded plug into the port
opening.
The total flow rate (QT) entering the

Regenerative Cylinder Circuit blank end of the cylinder equals the
pump flow rate (QP) plus the
regenerative flow rate (QR) coming
from the rod end of the cylinder:
Solving for the pump flow rate, we have

The total flow rate equals the piston area (AP)
multiplied by the extending speed of the piston
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 preceding
equation yields
The extending speed equals the pump flow rate divided by the area of the rod
a small rod area (which produces In fact the extending speed can be
a large regenerative flow rate) greater than the retracting speed
provides a large extending speed if the rod area is made small enough
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Ratio of Extending and

Regenerative Cylinder Circuit Retracting Speeds
The extending speed
The retracting speed
On further simplification we obtain

the desired equation:
• When the piston area equals two times the rod area,
the extension and retraction speeds are equal.
• 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 kept in mind that the load-carrying capacity
of a regenerative cylinder during extension is less than
that obtained from a regular double-acting cylinder.
Thus, we are not obtaining more power from the regenerative cylinder during extension
because the extending speed is increased at the expense of reduced load carrying capacity
Regenerative Cylinder Circuit

EXAMPLE 9-1 • The cracking pressure for the relief valve is 1000 psi.
• The piston area is 25 in2 and the rod area is 7 in2.
• The pump flow is 20 gpm.
• Find the cylinder speed, load-carrying capacity, and
power delivered to the load (assuming the load
equals the cylinder load-carrying capacity) during the
a. Extending stroke
b. Retracting stroke
Note that the hydraulic horsepower delivered

by the pump during both the extending and
retracting strokes can be found as follows:
Thus, as expected, the hydraulic power delivered by the pump equals the power delivered to the loads
during both the extending and retracting strokes.
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Regenerative Cylinder Circuit

Drilling Machine Application
1. The spring-centered position gives
 rapid spindle advance extension.
2. The left envelope mode gives

 slow feed extension when the drill starts
to cut into the workpiece.
3. The right envelope mode gives

 high speed of piston retraction.
• 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.
PUMP-UNLOADING CIRCUIT
• The unloading valve opens when
 the cylinder reaches the end of its stroke.
 the check valve keeps high-pressure oil in the
pilot line of the unloading valve. DCV
• The unloading valve resets when unloading

 the pressure in the pilot line of the unloading valve
valve reduced by the motion of the piston.
 This resets the unloading valve until the
cylinder is fully retracted, at which point the
unloading valve.
• Thus, 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.
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DOUBLE-PUMP HYDRAULIC SYSTEM

• A circuit uses in conjunction with
 a high-pressure, low-flow pump
 a low-pressure, high-flow pump.
• A typical application is a sheet metal punch press in

which
 A rapid extension of the cylinder (hydraulic ram)
o over a great distance with very low pressure but
high flow-rate requirements
o 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
 A short motion portion
o the cylinder travel is small and thus the flow-rate
requirements are low
o occurs in the punching operation, the pressure
requirements are high due to the punching load.

• A circuit uses in conjunction with
 a high-pressure, low-flow pump
 a low-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
when the DCV is in its spring-centered mode.
• The purpose of the check valve is to protect the low-pressure pump
from high pressure, during the punching operation, at the ends of the cylinder stroke
when the DCV is in its spring-centered mode.
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a 1.5-in-diameter piston
and 0.5-in-diameter rod
EXAMPLE 9-2 Required

punching
What should be the pressure settings of the unloading valve force is
2000 lb
and pressure relief valve under the following conditions?
• During rapid extension of the cylinder,
 a frictional pressure loss of 100 psi occurs in the line
from the high-flow pump to the blank end of the
cylinder.
 a pressure loss of 50-psi occurs in the return line from
the rod end of the cylinder to the oil tank during the
same time
• Assume that
 Frictional pressure losses in these lines are negligibly
small during the punching operation.
 the unloading valve and pressure relief valve pressure
settings (for their full pump flow requirements) should
be 50% higher than the pressure required to overcome
frictional pressure losses and the cylinder punching
load, respectively.
a frictional pressure
DOUBLE-PUMP HYDRAULIC SYSTEM loss of 100 psi a pressure loss
of 50-psi
Unloading Valve:
EXAMPLE 9-2 Back-pressure force on the cylinder equals the product of Required
punching
the pressure loss in the return line and the effective area force is
2000 lb
of the cylinder (Ap - Ar).
1132psi
Pressure at the blank end of the cylinder required to 1698 psi

overcome back-pressure force equals the back-pressure force
divided by the area of the cylinder piston. 217psi
1870 psi
240psi
Thus, the pressure setting of the unloading valve a 1.5-in-diameter piston
144.4psi and 0.5-in-diameter rod
should be 1.50 x (100 + 44.4) psi = 217 psi.
Pressure Relief Valve:
The pressure required to overcome
the punching operation equals
the punching load divided by
the area of the cylinder piston. Thus, the pressure setting of the pressure relief valve
should be 1.50 × 1132 psi = 1698 psi.
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COUNTERBALANCE VALVE APPLICATION

a frictional pressure loss of 100 psi
• A counterbalance valve (or back-
pressure valve) is used a 1.5-in-
 to keep a vertically mounted diameter
piston and
hydraulic cylinder 0.5-in-
 in the upward position diameter rod
105%
 while the pump is idling.
• The counter-balance valve (CBV)

is set 150%
 to open at somewhat above
Required
the pressure required force is
 to prevent the vertical cylinder 1000 lb
from descending due to the
weight of its load.
• The use of CBV permits • The DCV configuration is

 the cylinder to be forced  a solenoid-actuated,
downward  spring-centered valve
 when pressure is applied on  with an open-center flow path to
the top. unload the pump
HYDRAULIC CYLINDER SEQUENCING CIRCUITS Required

force is
• Two sequence valves are used to 1000 lb Required
control the sequence of a 1.5-in-diameter piston
force is
1000 lb
operations of two double-acting and 0.5-in-diameter rod
cylinders.
• When the DCV is shifted into its left envelope mode,

 the left cylinder extends completely,
 and then the right cylinder extends.
• If the DCV is then shifted into its right envelope mode,
 the right cylinder retracts fully,
 and then the left cylinder retracts.
• The sequence of cylinder operation is controlled by the sequence valves.
• The spring-centered position of the DCV locks both cylinders in place.
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HYDRAULIC CYLINDER SEQUENCING CIRCUITS

• Two sequence valves are used to
control the sequence of
operations of two double-acting
cylinders.
• One application of this circuit is

a production operation.
• For example,
 The left cylinder could extend to 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.
 These machining operations must occur
o in the proper sequence
o as established by the sequence valves in the circuit.
LOCKED CYLINDER USING PILOT CHECK VALVES

• In many cylinder applications, it is necessary to lock
the cylinder so that its piston cannot be moved due
to an external force acting on the piston rod.
• One method for locking a cylinder is by using pilot

check valves.
• The cylinder can be extended and retracted as

normally done by the action of the directional
control valve (DCV).
• If regular check valves were used,

 the cylinder could not be extended or retracted
by the action of the DCV.
 An external force, acting on the piston rod, will
not move the piston in either direction
 because reverse flow through either pilot check
valve is not permitted under these conditions.
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CYLINDER SYNCHRONIZING CIRCUITS

Cylinders Connected in Parallel
Cylinders hooked in parallel will not operate in synchronization

Cylinders Connected in Series
Cylinders hooked in series will operate in synchronization
CYLINDER SYNCHRONIZING CIRCUITS

Cylinders Connected in Series Cylinders hooked in series will
operate in synchronization
Since Q = Aυ where A is the effective area

through which fluid flows, we have
Since for synchronization υ1 = υ2, we have the desired result:
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 extending cylinders.
The pressures are equal at the blank end of cylinder 2 and at the rod end of cylinder 1 per Pascal’s law:
Summing forces on cylinder 1 yields
Summing forces on cylinder 2 yields
Adding the preceding two equations together and noting that
and that p3 = 0 (due to the drain line to the tank), we obtain the desired result
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FAIL-SAFE CIRCUITS
Protection from Inadvertent Cylinder Extension
• Fail-safe circuits are designed to prevent
 injury to the operator or damage to equipment.
 the system from accidentally falling on an
operator, and
 overloading of the system.
• To lower the cylinder,
 pilot pressure from the blank end of the
piston must pilot-open the check valve at
the rod end to allow oil to return through
the DCV to the tank.
• This happens
Figure shows a fail-safe circuit that prevents the cylinder from
• when the push-button valve is actuated to
accidentally falling in the event of
permit pilot pressure actuation of the DCV
 a ruptured hydraulic line or
• or when the DCV is directly manually
 a person inadvertently operating to the manual override on
actuated while the pump is operating.
the pilot actuated directional control valve
 when the pump is not operating.
• The pilot-operated DCV allows free flow in the
opposite direction to retract the cylinder when
this DCV returns to its spring-offset mode.
FAIL-SAFE CIRCUITS
Fail-Safe System with Overload Protection
• Directional control valve 1 is controlled by push-button,
three-way valve 2.
• When overload
 valve 3 is in its spring-offset mode,
 it drains the pilot line of valve 1.
• If the cylinder experiences excessive resistance during

the extension stroke,
 sequence valve 4 pilot-actuates overload valve 3.
 This drains the pilot line of valve 1, causing it to
return to its spring-offset mode.
• If a person then operates push-button valve 2,

 nothing will happen
 unless overload valve 3 is manually shifted into its
blocked port configuration.
• Thus, the system components are protected against

excessive pressure due to an excessive cylinder load
during its extension stroke.
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FAIL-SAFE CIRCUITS
Two-Handed Safety System
• The safety circuit is designed to protect an operator from injury.
• For the circuit to function (extend and retract the cylinder), the
operator must depress both manually actuated valves via the push
buttons.
• Furthermore, the operator cannot circumvent this safety feature by

tying down one of the buttons, because it is necessary to release
both buttons to retract the cylinder.
• When the two buttons are depressed, the main three-position

directional control valve is pilot-actuated to extend the cylinder.
• When both push buttons are released, the cylinder retracts.
SPEED CONTROL OF A HYDRAULIC CYLINDER

A speed control of a hydraulic cylinder is accomplished during
the extension stroke using a flow control valve.
The pressure drop versus flow rate for a needle valve:
Meter-in speed control of hydraulic cylinder

during extending stroke using flow control valve
(DCV is in manually actuated position.)
Operation
1. When the directional control valve is actuated,
• 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 (FCV).
2. When the directional control valve 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.
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The flow rate through the flow control valve
(FCV) is governed by

The flow rate to the cylinder equals during extending stroke using flow control valve
pump flow rate minus the flow rate (DCV is in manually actuated position.)
through the PRV.
Also, pressure p3 = 0, Pressure p2 can be obtained by

summing forces on the hydraulic cylinder
Also, the extending speed of the cylinder through

the flow control valve as follows:
Combining the preceding equation yields the final result.
by varying the setting of the flow control valve,

and thus the value of Cv, the desired extending speed of the cylinder can be achieved.

Meter-in systems are used primarily when the external load opposes
the direction of motion of the hydraulic cylinder.
Meter-out system is generally preferred over the

meter-in system as in the case of a weight pulling
downward on the piston rod of a vertical cylinder.
In this case the weight would suddenly drop by

Meter-in speed control of hydraulic cylinder pulling the piston rod down if a meter-in system is
during extending stroke using flow control valve used even if the flow control valve is completely
(DCV is in manually actuated position.) closed.
• One drawback of a meter-out system is the

possibility of excessive pressure buildup in the
rod end of the cylinder while it is extending.
• 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 produces the undesirable effect of a high Meter-out speed control of hydraulic cylinder
heat generation rate with a resulting increase during extending stroke using flow control valve
in oil temperature. (DCV is in manually actuated position.)
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Meter-in systems are used primarily when the external load opposes
the direction of motion of the hydraulic cylinder.

during extending stroke using flow control valve
(DCV is in manually actuated position.)

For the meter-out system of Figure, which uses a suspended load,
determine the pressure on each pressure gage during constant
speed extension of the cylinder for
a. No load
b. 20,000-N load
The cylinder piston and rod diameters are 50 mm
and 25 mm, respectively,
and the PRV setting is 10 MPa.
During extension (load is lowered)

 the flow rate to the cylinder is less than the
pump flow rate
 due to the operation of the flow control valve
 to achieve the desired cylinder speed. For a constant speed cylinder, the total net force acting on the
The excess flow goes through the PRV. piston and rod combination must equal zero.
Thus, during extension, p1 equals approximately the Thus, for no load, we have
pressure relief valve setting of 10 Mpa.
This means that the downward hydraulic force
acting on the cylinder piston equals the pressure
relief valve setting of 10 MPa multiplied by the
cylinder piston area.
Finally, p3 equals approximately zero because of in the return
pipeline via the DCV
(assumes negligibly small pressure drops through the DCV and the
pipeline connecting the pump to the blank end of the cylinder).
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For the meter-out system of Figure, which uses a suspended load,
determine the pressure on each pressure gage during constant
speed extension of the cylinder for
a. No load
b. 20,000-N load
The cylinder piston and rod diameters are 50 mm
and 25 mm, respectively,
and the PRV setting is 10 MPa.
During extension (load is lowered)

 the flow rate to the cylinder is less than the
pump flow rate
 due to the operation of the flow control valve
 to achieve the desired cylinder speed. For a constant speed cylinder, the total net force acting on the
The excess flow goes through the PRV. piston and rod combination must equal zero.
Thus, during extension, p1 equals approximately the Thus, for load, we have
pressure relief valve setting of 10 Mpa.
This means that the downward hydraulic force
acting on the cylinder piston equals the pressure
relief valve setting of 10 MPa multiplied by the
cylinder piston area.
Finally, p3 equals approximately zero because of in the return
pipeline via the DCV
For the case where the load equals 20,000 N, pressures p1 and p3 are the same as that found for the no-load case.
However, pressure p2 is found once again by noting that the total net force acting on the piston and rod combination
must equal zero.
SPEED CONTROL OF A HYDRAULIC MOTOR

1. In the spring-centered position of the tandem four-way valve, the
motor is hydraulically locked.
2. When the four-way valve is actuated into the left envelope,
 the motor rotates in one direction.
 Its 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 through the pressure relief valve.
3. When the four-way valve is deactivated,
 the motor stops suddenly and becomes locked.
4. When the right envelope 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.
Speed control of hydraulic motor using

pressure-compensated flow control valve.
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HYDRAULIC MOTORS
It is a device that converts the hydraulic energy (power)
generated by a pump into mechanical energy (power) in the
form of torque and rotation (rpm)
For a Hydraulic Pump, the main function is to -Displace as

much oil as possible per revolution.
To achieve this an optimum volumetric efficiency at the cost of
mechanical efficiency is required.
On the other hand, the Hydraulic Motors have to deliver
maximum mechanical power at the load point.
HYDRAULIC MOTORS Graphical Symbols
Envelope
In Out
Dotted Line Uni - Directional

for Drain Hyd. Motor
– Fixed Displacement
Solid
Triangle
( Hydraulic )
Variable Displacement
Bi - Directional Bi - Directional
Hyd. Motor Hyd. Motor
– Fixed Displacement
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SALIENT FEATURES OF A HYDRAULIC MOTOR
 Extreme range of speed adjustment possible.

 Torque control throughout the operating speed.
 Low Inertia.
 Compactness of space.
 The fact that they can be stalled indefinitely without damage.
 Instant reversing of the motor’s shaft.
 Dynamic braking is easily accomplished.
Rapid Reversal
The Rotor Mass of

Hydraulic Motor  Electric Motor
176
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Rapid Reversal
177
Rapid Reversal
178
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Speed Variation
Electric Motor  Torque Converters

Hydraulic Motor  Simple Flow Control Valve
179

Speed Variation
Electric Motor  Torque Converters

Hydraulic Motor  Simple Flow Control Valve
Size Comparison
Power Density of
Hydraulic Motor  Electric Motor
180
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Stall Performance
Electric Motor  Trips / Stops

Hydraulic Motor  Stall Torque possible to achieve
181
Stall Performance
182
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Unfavourable Environment
Fluid Motors can be used in Dangerous,
Difficult environment.
Speed Regulation
Speed = No Load - Loaded
Regulation Speed Speed x 100
No Load Speed
Speed Variations
Electric Motor  3 %
Most Hyd. Motors  10 - 15 %
(Except for Radial Piston Motors )
183
MAJOR APPLICATIONS
CONSTRUCTION
MINING
MATERIAL HANDLING
EARTH MOVING
PLASTICS
MACHINE TOOLS
AGRICULTURE
RAILWAY EQUIPMENT
184
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MAJOR APPLICATIONS
Special Purpose Vehicle using Hydraulic Drive
Winches
185
MAJOR APPLICATIONS
Fan Drives
Batch Mixers
Conveyor
Drives
186
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WHILE REPLACING AN ELECTRIC MOTOR

WITH A HYDRAULIC MOTOR
Points to be considered :
3 Phase Squirrel cage Electric Motor has

twice the starting torque of a Hydraulic Motor.
The value of the starting torque/running
torque is to be known.
Do not consider HP as a comparison
The details of the Gear Box and pulley used

at output of the Electric Motor to be known.
187
CLASSIFICATION OF HYDRAULIC MOTORS

GEOMETRY OF THE ACTUATING MECHANISM
SPEED AND TORQUE RATING
HIGH TORQUE LOW TORQUE

LOW SPEED MOTORS HIGH SPEED MOTORS
( HTLS ) ( LTHS )
RADIAL PISTON MOTORS AXIAL PISTON MOTORS
CRANKSHAFT SWASH PLATE

CAM - LOBE BENT AXIS
ORBIT MOTORS GEAR MOTORS

GEROTOR
VANE MOTORS
GEROLLER
188
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GEAR MOTORS
COMPACT
LOW COST
LOW EFFICIENCY ( 60% - 70% )
SPEED RANGE ( 500 – 3000 rpm )
CANNOT BE USED FOR LOW SPEED
189

GEAR MOTORS
190
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MOTOR RATINGS
The rating of hydraulic motors is done based on the following
operating parameters :
Displacement
Torque capacity
Speed
Operating Pressure
Displacement : of a hydraulic motor is defined as the

amount of fluid required to turn the motor shaft by one
revolution.
191

MOTOR RATINGS
Torque: Torque is the turning force developed at the motor
shaft due to its rotation. The value of Torque increases with
an increase in operating pressure, and decreases when the
pressure decreases.
Speed: The speed of a hydraulic motor depends on its

displacement and the flow rate to it.
Operating Pressure : The pressure required by a hydraulic

motor depends on the torque requirement and its displacement
192
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MOTOR SELECTION
OUTPUT PARAMETERS :  SPEED ( RPM )

 TORQUE ( KG – M )
MOTOR PARAMETER :  DISPLACEMENT ( CC / REV. )
HYD. PARAMETERS :  FLOW ( LPM )
 PRESSURE ( BAR )
TORQUE :  DISPLACEMENT X PR. X m
628
SPEED :  FLOW X 1000 X V
DISPLACEMENT
193
EFFECT ON HYDRAULIC MOTOR DURING

CHANGE IN HYD. SETTINGS UNDER CONSTANT
LOAD CONDITION
CHANGE SPEED EFFECT ON TORQUE

OPERATING AVAILABILITY
PRESSURE
Increase pressure setting No Effect No Effect Increases
Decrease pressure setting No Effect No Effect Decreases
Increase flow Increases No Effect No Effect
Decrease flow Decreases No Effect No Effect
Increase displacement (Size) Decreases Decreases Increases
Decrease displacement (Size) Increases Increases Decreases
194
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SPEED CONTROL OF A HYDRAULIC MOTOR

Speed control of hydraulic motor using
pressure-compensated flow control valve
This is called open-circuit drives because the

pump draws its fluid from a reservoir. Its output is
then directed to a hydraulic motor and discharged
from the motor back into the reservoir.
actually hydrostatic transmissions
HYDRAULIC MOTOR BRAKING SYSTEM

This is called open-circuit
drives because the pump
draws its fluid from a
reservoir. Its output is
then directed to a
hydraulic motor and
discharged from the motor
back into the reservoir.
actually hydrostatic transmissions
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HYDROSTATIC TRANSMISSION SYSTEM

Closed-circuit,
one-direction hydrostatic transmission.
Closed-circuit, reversible-direction
hydrostatic transmission
99

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12/17/2023

In the 17th century Pascal developed the law of confined fluids.

Pascal’s Law, simply stated, says:

“Pressure applied on a confined fluid

“Pressure applied on a confined fluid is transmitted undiminished in all directions,

Pascal’s Law: A Closer Look

Pascal’s Law Explained Using A Fulcrum

Explaining Piston Displacement

Example: Figure shows

a pressure of 50 psi being applied to

F = 50 (psi) x 100 (sq in) = 5,000 (pounds)

Solving For Pressure F

231 cubic inches

Energy transfer into and out

Energy transfer into and out of a

Example of hydraulic circuit with symbols

Pumping action of a simple piston pump

Oil has Weight

Using the Weight of Oil to help feed a Pump

Air Intake From Loose Connections

Charged from oil above Vacuum required to feed pump

When There Is No Movement Of Oil

How Pressure Is Lost Through An Orifice

Larger Orifices Steal Less Pressure Or Work

Flow Blocked, Pressure Equalized!

Fast Moving Oil May Become Turbulent

Slow Moving Oil

Basic Symbols of Hydraulics

Basic Symbols: Lines

Square, Rectangle, Diamond

squares - control components

diamond – Condition apparatus (filter,

Fixed Displacement Hydraulic

Bidirectional (rotates in both directions)

Reading Symbols For Pumps And Motors

Reading Symbols For Cylinders

Symbols For Pilot Operated Relief Valves

Understanding Reservoir Lines And Symbols

Spool Valve Positions- Finite & Transition

in/out Stop Reverse Directions

Example of hydraulic circuit with symbols

1. Cylinder 6. Hydraulic Pump

Hydraulic Pumps / Motors

Hydraulic Power Units

2. Positive displacement pumps (Bơm thể tích)

The output flow rate is reduced

3. Piston pumps (fixed or variable displacement)

GEAR PUMPS - External Gear Pump

The theoretical flow rate (in English units)

Since 1 gal 231 in3, we have

Using Metric Units, we have

GEAR PUMPS - External Gear Pump

Solution Find the displacement volume

Since 1 gal 231 in3, we have

Using Metric Units, we have

GEAR PUMPS - External Gear Pump

Solution The volume displacement is

Since 1 L = 0.001 m3, VD 0.0614 L

Since 1 L = 0.001 m3, we have

GEAR PUMPS - Internal Gear Pump

GEAR PUMPS - Lobe Pump

• Both lobes are driven externally so that they do not