Worksheets Hydraulics Basic Level

Table of contents
Exercises and work sheets
Exercise 1: Setting up a hydraulic workstation _________________________________________________3

Exercise 2: Commissioning a two-column hydraulic press ______________________________________ 13
Exercise 3: Measuring the characteristic pump curve __________________________________________ 21
Exercise 4: Measuring the opening characteristics of a pressure-relief valve _______________________ 33
Exercise 5: Unloading a paper machine _____________________________________________________ 41
Exercise 6: Opening a hardening furnace ____________________________________________________ 51
Exercise 7: Opening and closing a boiler door ________________________________________________ 59
Exercise 8: Dimensioning an assembly device ________________________________________________ 69
Exercise 9: Sorting shipping crates_________________________________________________________ 73
Exercise 10: Measuring the characteristic curve of a flow control valve_____________________________ 83
Exercise 11: Adjusting stroke speed at a hydraulic lift __________________________________________ 93
Exercise 12: Optimising an embossing machine ______________________________________________ 103
Exercise 13: Matching retracting and advancing speed ________________________________________ 115
Exercise 14: Securing a cylinder against unintentional retraction ________________________________ 123
Exercise 15: Correcting misalignment of a conveyor belt _______________________________________ 133
Exercise 16: Counter-pressure for closing a bulkhead door _____________________________________ 139
Exercise 17: Loading and unloading buckets _________________________________________________ 145
© Festo Didactic 551141 1

Table of contents
2 © Festo Didactic 551141

Exercise 1:
Setting up a hydraulic workstation
Learning objectives
After completing this exercise:
• You will be familiar with the setup and function of a hydro pump.
• You will be familiar with the most important characteristics of a hydro pump.
• You will be able to select a hydraulic power unit on the basis of specified requirements.
Problem description
A new hydraulic workstation needs to be set up in the training department. Size NG 4 products are used.
Maximum operating pressure is limited to 6 MPa (60 bar). A 230 V AC electrical outlet is available. A suitable
hydraulic power unit must be selected.
Layout

Exercise 1 – Setting up a hydraulic workstation
Assignments
1. Describe the setup and function of a hydro pump.
2. Calculate the volumetric flow rate of a hydro pump.
3. Calculate the efficiency of a hydro pump.
4. Select a hydraulic power unit on the basis of specified requirements.
Work aids
• Data sheets
• Hydraulics textbook
1. Setup and function of a hydro pump
Information
Hydro pumps are displacement pumps which function on the basis of “suction and displacement”.
We differentiate amongst three basic types of hydro pumps on the basis of displacement volume:
• Constant displacement pump Constant displacement volume
• Variable displacement pump Adjustable displacement volume
• Control pump: Displacement volume is controlled on the basis of
pressure, volumetric flow rate and power
The hydro pump generates volumetric flow (but no pressure). The delivery rate per revolution and
the drive speed dictate the pump’s delivery rate which is specified in litres per minute.
Pressure only occurs as the result of resistance to pump delivery, for example flow resistance, load
resistance and pressure-relief valve settings. Pressure is specified in MPa or bar.
4 Name: __________________________________ Date: ____________ © Festo Didactic 551141

a) Describe the function of the gear pump shown in the figure.
Gear pump – cutaway view; 1: trapped fluid, 2: pressure chamber, 3: suction chamber
© Festo Didactic 551141 Name: __________________________________ Date: ____________ 5

b) Name the circuit symbols shown below and briefly describe the functions of the components.
1 2 3
P T
Hydraulic power unit – circuit symbol

c) Match up the individual components of the hydraulic power unit with the corresponding numbers in the
drawing.
Hydraulic power unit – schematic diagram
Component no. Component (designation)
Drain screw
Suction chamber
Suction tube
Vent with air filter
Moderating plate
Filling filter
Fill-level indicator, maximum fill-level
Fill-level indicator, minimum fill-level
Motor and pump
Return
Return chamber

2. Calculating the volumetric flow rate of a hydro pump
Information
Displacement volume V (also known as delivery rate or swept volume) is a measure of the size of
the pump. It designates the liquid volume which is delivered by the pump per revolution (or stroke).
The delivered liquid volume per minute is designated volumetric flow rate q. This results from
displacement volume V and speed in rpm n:
q= n ⋅ V
– Calculate the volumetric flow rate of a gear pump.
Given
Speed n = 1450 rpm
Displacement volume V = 2.8 cubic cm (per revolution)
Desired
Flow rate q in l/min.
Calculation

3. Calculating the efficiency of a hydro pump
Information
Mechanical power is converted to hydraulic power by pumps, during which power losses occur that
are expressed in terms of the pump’s degree of efficiency.
Effective power Phyd generated by the pump depends upon operating pressure p and effective
volumetric flow rate qeff. Effective power is calculated with the equation:
Phyd= p ⋅ qeff
Volumetric efficiency is the relationship between the pump’s effective volumetric flow rate and its
theoretically calculated volumetric flow rate.
q
ηvol =eff
qth
q=
th Vth ⋅ n
qeff= Vth ⋅ n ⋅ ηvol
– Calculate the efficiency of a hydro pump.
Given
Speed n = 1450 rpm
Displacement volume V = 6.5 cubic cm (per revolution)
l
Effective volumetric flow rate qeff = 8.6 at 100 bar
min
Desired
Efficiency ηvol
Calculation

4. Selecting a hydraulic power unit
Information
Excerpts from three data sheets for hydraulic power units are included below. Select the power unit
which fulfils the following conditions:
• Drive motor with 230 V nominal voltage
• Frequency: 50 Hz
• Delivery rate at nominal speed: 2.2 l/min.
• Weight without oil: max. 20 kg
General HA-5L-230-50 HA-5L-110-60 HA-20L-400-50
Dimensions
Length 580 mm 580 mm 580
Width 300 mm 300 mm 300
Height 180 mm 180 mm 180 mm
Weight
Empty 19 kg 19 kg 19 kg
With oil 24 kg 24 kg 29 kg
Electrical specifications HA-5L-230-50 HA-5L-110-60 HA-20L-400-50
Motor Alternating current, single- Alternating current, single- Alternating current, 3-phase
phase phase
Nominal power 650 W 550 W 550 W
Nominal voltage 230 V 110 V 400 V
Frequency 50 Hz 60 Hz 50 Hz
Nominal speed 1320 rpm 1680 rpm 1390 rpm
Protection IP 20 IP 20 IP 20
Duty cycle 50% 50% 100%

Hydraulics HA-5L-230-50 HA-5L-110-60 HA-20L-400-50
Medium Mineral oil, recommended: 22 cSt (sq. mm / s)
Pump design External gear pump
Geometric delivery rate 1.6 cubic cm 1.6 cubic cm 1.6 cubic cm
Delivery rate at nominal speed 2.2 l/min. 2.7 l/min. 2.2 l/min.
Operating pressure 0.5 to 6 MPa (5 to 60 bar)
Adjustment Manual
Pressure gauge indicating range 0 to 10 MPa (0 to 100 bar)
Pressure gauge quality class 1.6
Oil tank capacity Approx. 5 litres Approx. 5 litres Approx. 10 litres
Return filter filtration grade 90 µm
Connection One quick coupling socket each for P and T, one coupling for the line to the storage tank, one
connection for the discharge measuring receptacle
– Which hydraulic power unit have you chosen? Give reasons for your selection.


Exercise 2:
Commissioning a two-column hydraulic press
Learning objectives
• You will be familiar with the various types and possible uses of pressure-relief valves.
• You will able to safely commission hydraulic controllers.
Problem description
During practice operation and for industrial maintenance purposes, safe commissioning is undertaken at low
pressure which is then increased up to the maximum value. This is possible with either a pressure-relief valve
or a pump bypass circuit. At low pressure, leaks can be safely detected after device replacement, for example.
The press has been set up for the specified application and initial start-up must now take place.
Layout
Two-column hydraulic press

Exercise 2 – Commissioning a two-column hydraulic press
Prerequisites
Safety equipment which is required in actual practice (e.g. two-hand controls, protective guard) are not
taken into consideration in this exercise.
Assignments
1. Describe the various types and possible uses of pressure-relief valves.
2. Familiarise yourself with the commissioning procedure.
3. Inform yourself regarding the procedure for adjusting pressure-relief valves.
4. Complete the hydraulic circuit diagram.
5. Create the equipment list.
6. Set up the controller.
7. Double check the controller configuration.
Visual inspection
Continuous visual inspection for defects in hoses and hydraulic devices is an essential part of
hydraulic safety standards.
Work aids
• Data sheets
• FluidSIM® H simulation software

1. Types and possible uses of pressure-relief valves
a) What purpose do pressure-relief valves serve?
b) Name various types of pressure-relief valves.
c) Why are pressure-relief valves used in hydraulic systems?

2. Commissioning procedure
Information
Commissioning procedure (pump bypass circuit)

1 Switch to pump recirculation by opening the on-off valve.
2 In the case of electro-hydraulic controllers, activate 24 V DC control voltage.
3 Switch the hydraulic pump on.
4 Slowly close the on-off valve until a circulating pressure of approximately 1.5 MPa prevails.
Immediately set the pump back to recirculation in the event of leaks.
5 Run the sequence once and watch for leaks.
6 Close the on-off valve and do the exercise.
Commissioning procedure (circuit with pressure-relief valve)

1 Fully open the on-off pressure-relief valve.
2 Activate 24 V DC control voltage.
4 Slowly close the pressure-relief valve until a circulating pressure of approximately 1.5 MPa
prevails.
5 Run the sequence once and watch for leaks.
6 Close the pressure-relief valve until the required pressure limit is reached.
3. Adjusting pressure-relief valves
Information
Procedure for pump bypass circuit

1 Open the on-off valve.
3 Close the on-off valve.
The entire volume delivered by the pump is discharged via the pressure-relief valve at the
hydraulic power unit. The momentary pressure limit setting is indicated at the pressure gauge.
4 Correct the value by opening or closing the pressure-relief valve to the specified pressure limit
(e.g. 5 MPa).

Procedure for circuit with pressure-relief valve

1 Open the pressure-relief valve.
2 Close the on-off valve.
4 The entire volume delivered by the pump is discharged via the pressure-relief valve. The
momentary pressure limit setting is indicated at the pressure gauge.
5 Correct the value by opening or closing the pressure-relief valve to the specified pressure limit
(e.g. 5 MPa).
6 Open the on-off valve.
4. Hydraulic circuit diagram
a) Complete the hydraulic circuit diagram for the first commissioning circuit (pump bypass circuit).
1V1
A B
0Z2 0Z3
0Z1 P T

b) Complete the hydraulic circuit diagram for the second commissioning circuit
(circuit with pressure-relief valve).
1V2
A B
1V1
0Z2 0Z3
0Z1 P T

5. Creating the equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Create an equipment list by entering the required number of components and the abbreviations used to
identify them in the circuit diagram to the table below.
Quantity Identification Designation
One-way flow control valve
On-off valve
600 mm length of hose
4-way manifold plate with pressure gauge
Hydraulic power unit
Equipment list, pump bypass circuit
On-off valve
Pressure-relief valve
Equipment list, circuit with pressure-relief valve

6. Setting up the controller (pump bypass circuit)

Observe the following points when setting up the controller:
• Use the circuit diagram.
• Designate the components.
• Connecting hose lines
– Never connect or disconnect hose lines when the hydraulic power unit is running, or while under
pressure!
Couplings must be connected in the unpressurised state.
– Set the coupling socket squarely onto the coupling nipple!
The coupling socket and the coupling nipple must not be fitted askew.
• Selecting and laying hose lines
– Select the hose line length such that adequate leeway is available in order to accommodate
changes in length which result from pressure.
– Avoid mechanical stressing of the hose line.
– Do not bend the hose line into a radius of less than its specified minimum bending radius of 51 mm.
– Do not twist the hose line during installation.
– Make sure that hose lines do not become kinked.
• Mark the completed hose connections in the hydraulic circuit diagram.
7. Double checking the controller setup (pump bypass circuit)

Observe the following points when commissioning the controller:
• Before commissioning, make sure that all tank lines have been connected and that all couplings have
been securely fitted.
• Fully close the throttle at one-way flow control valve 1V1.
• Switch to pump recirculation by opening on-off valve 0V1.
• Switch the hydraulic power unit on.
• Slowly close the on-off valve until a circulating pressure of approximately 1.5 MPa has been built up.
• Fully close the on-off valve and set the pressure limit at the hydraulic power unit’s pressure-relief valve
to a value of 5 MPa.
• Open the throttle by one half of one revolution. Hydraulic fluid flows through the one-way flow control
valve to the tank port.
Note
Before dismantling the controller, fully close the throttle at the one-way flow control valve.

Exercise 3:
Measuring the characteristic pump curve
Learning objectives
• You will be able to record and interpret the characteristic curve of a hydraulic pump.
• You will be able to measure the volumetric flow rate in hydraulic controllers.
• You will be familiar with the relationship between pump delivery rate and operating pressure.
Problem description
The main spindle of an injection moulding machine is driven by means of a hydraulic motor, and feed motion
for the tool carriage is executed with a hydraulic cylinder at the same time. It has been determined that the
hydraulic motor no longer reaches its specified speed during the processing operation. The characteristic
pump curve needs to be measured in order to rule out the possibility of a defective hydraulic pump.
Layout
Plastic injection moulding machine

Exercise 3 – Measuring the characteristic pump curve
Assignments
1. Inform yourself regarding the fundamentals of volumetric flow and its measurement.
2. Calculate the rate of volumetric flow through a hydraulic motor.
3. Draw the hydraulic circuit diagram.
7. Record the characteristic curve of the hydraulic pump.
8. Interpret the characteristic curve of the hydraulic pump.
Visual inspection
Work aids
• Data sheets
• Operating instructions

1. Measuring volumetric flow rate
Information
Volumetric flow rate

The volumetric flow rate is the volume of liquid which flows through a pipe within a specified period
of time.
Example
It takes about one minute to fill a 10 litre bucket at a water faucet. The faucet’s volumetric flow rate
is thus 10 litres per minute.
In the field of hydraulics, the volumetric flow rate is designated q. The following definitions apply:
V
q=
t
q volumetric flow rate [cubic metres per sec.]

V Volume [cubic metres]
t Time [seconds]
Measuring the volumetric flow rate

A simple measuring method involves the use of a calibrated vessel and a stopwatch.
Turbine and rotating-vane flow meters are recommended for continuous measurement. Volumetric
flow rate can be determined on the basis of the speed in rpm indicated at these meters. Speed in
rpm and the volumetric flow rate have a proportional relationship.
Volumetric flow rate can be measured in accordance with the back pressure principle with the help
of a float. The use of an orifice flow meter is a further option. The pressure drop ascertained at the
orifice is a measure of the volumetric flow rate (pressure drop and volumetric flow rate have a
proportional relationship). Measurement with an orifice is hardly influenced at all by the viscosity of
the hydraulic fluid.

Hydraulic motors
Hydraulic motors are components of the drive section. They are power components (actuators).
They convert hydraulic energy into mechanical energy and cause rotary motion (rotary drive). If
rotary motion is confined to a certain angle range, we speak of oscillating motors.
As a rule, hydraulic motors are based on the same engineering design as hydro pumps. They are
subdivided into:
• Fixed displacement motors Constant displacement volume
• Adjustable motors Adjustable displacement volume
Hydraulic motors have the same characteristic values as pumps. Displacement volume is specified
in cubic centimetres per revolution by hydraulic motor manufacturers, and the speed range within
which the motor works efficiently is indicated as well. The following applies to hydraulic motor
displacement volume:
M
p=
V
q=n⋅V
p pressure [Pa, MPa]

M torque [Nm]
V geometric displacement, displacement volume [cubic cm]
q volumetric flow rate [cubic dm / min.]
n speed [rpm]
The volumetric flow rate required by the motor is calculated on the basis of the displacement
volume and the desired speed in rpm.

2. Calculating the volumetric flow rate
a) A motor with a displacement volume of V = 8.2 cubic cm will be used to measure volumetric flow rate.
The speed of the motor is measured in rpm. Set up the equation for calculating the pump’s volumetric
flow rate.
b) What is the rotational speed of the motor, when the pump delivers 2.3 cubic dm per minute?

– Complete the hydraulic circuit diagram for measuring the characteristic pump curve.
0Z2 0Z3
0V1
0Z1 P T

Pressure gauge
Hydraulic motor
Flow sensor, connected to the hydraulic motor
On-off valve
Note
You will need the following items in order to perform the measurements:
• One 24 V DC power pack, max. 4.5 A
• One digital multimeter
5. Setting up the controller

pressure!


6. Double checking the controller setup

• Fully close the throttle at one-way flow control valve 1V1.
• Switch to pump recirculation by opening the on-off valve.
• Switch 24 V DC electrical supply power to the flow sensor on.
Note
Information regarding the flow sensor can be found in its operating instructions.

• Slowly close the on-off valve until a circulating pressure of approximately 1.5 MPa has been built up.
• Fully close the on-off valve and set operating pressure at the hydraulic power unit’s pressure-relief valve
to a value of 6 MPa.
7. Recording the characteristic curve
Execution
Fully open the throttle at one-way flow control valve 1V1. Pressure values, which can be read from
pressure gauge 1Z1, are adjusted by slowly closing the throttle.

a) Set pressure to the specified values and enter the measured flow rates to the table.
System pressure p [MPa] Flow rate q [l/min.]
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
Note
Before dismantling the controller, fully close the throttle at the one-way flow control valve.
b) Transfer the values to the characteristic pump curve.
2.4
l/min
q
2.3
2.2
2.1
0 1 2 3 4 MPa 5
p
Characteristic pump curve

8. Interpreting the characteristic curve
Information
The curve based on volumetric flow rate relative to pressure is the characteristic pump curve. The
characteristic pump curve makes it apparent that the effective volumetric flow rate (qeff) is reduced
as pressure increases. The actual volumetric flow rate (qw) is determined by taking pump leakage oil
(qL) into consideration.
A small amount of leakage oil flow is required within the pump for lubrication purposes.
The following can be deduced from a characteristic pump curve:

Where p = 0: the pump delivers the full volumetric flow rate q.
Where p > 0: q becomes smaller due to pump leakage oil.
The shape of the characteristic curve provides us with information regarding the pump’s degree of
volumetric efficiency (ηvol).
In order to use hydraulic pumps correctly, the above described characteristic values and
characteristic curves must be known – this makes it easier to compare various devices and select a
suitable pump.
a) Compare the characteristic curves of two hydraulic pumps – one new and one used.
10.0
l/min 1
q
9.6
9.4
9.2 2
9.0
8.8
8.6
8.4
0
0 5 10 15 20 MPa 25
p
Characteristic pump curves, 1: new hydraulic pump, 2: used hydraulic pump

b) Now calculate the degree of volumetric efficiency for the new pump. Take the required values from the
characteristic pump curve.
c) Now calculate the degree of volumetric efficiency for the used hydraulic pump. Take the required values
from the characteristic pump curve.


Exercise 4:
Measuring the opening characteristics of a pressure-relief valve
Learning objectives
• You will be familiar with the setup and function of a pressure-relief valve.
• You will be able to record the characteristic curve of a pressure-relief valve.
Problem description
Due to a change in the product range, heavier packages than originally planned now have to be raised with a
lift. This has resulted in reduced stroke speed. The pressure level at which division of pump delivery flow
begins now needs to be determined on the basis of the characteristic pressure/flow-rate curve of the
pressure-relief valve.
Layout
Package lift

Exercise 4 – Measuring the opening characteristics of a pressure-relief valve
Assignments
1. Describe the setup and function of a pressure-relief valve.
2. Draw the hydraulic circuit diagram.
6. Record the characteristic curve of the pressure-relief valve.
Visual inspection
Work aids
• Data sheets

1. Setup and function of a pressure-relief valve
Information
The pressure of any given system is selected and limited with these valves. Pilot pressure is
detected at the valve’s inlet (P).
– Describe the function of the pressure-relief valve.
Pressure-relief valve – cutaway view

– Complete the hydraulic circuit diagram for measuring the characteristic opening curve. Supplement any
incomplete circuit symbols. Identify the individual components and enter the missing port designations.
1M1
0V1

Pressure gauge
Hydraulic motor
On-off valve
Note

pressure!



• Fully open pressure-relief valve 1V1.
Note

• Slowly close the on-off valve. Immediately set the pump back to recirculation in the event of leaks.
• Fully close the on-off valve.
• Set the pressure-relief valve at the hydraulic power unit to a value of 6 MPa.

6. Recording the characteristic curve
Execution
Close pressure-relief valve 1V1 until a value of 5 MPa (50 bar) is indicated at pressure gauge 1Z1.
Fully open on-off valve 0V1.
Set pressure to each of the values specified in the table below by closing on-off valve 0V1 step by
step, and measure the volumetric flow rate for each value. At the same time, determine at which
pressure the pressure-relief valve starts to open.
a) Record your measured values and enter them to the table.
System pressure p [MPa] Flow rate q [l/min.]
4.0
4.2
4.4
4.6
4.8
5.0

b) Enter the measured values to the diagram. Interpret your results.
MPa
p
4.5
3.5
3
0 0.5 1 1.5 2 l/min 2.5
q
Information
A pressure increase is caused upstream from the flow control valve by reducing its flow cross-
section. This causes the pressure-relief valve to open, thus resulting in a division of flow. Due to
this division of flow, the quantity required for the desired speed in rpm flows to the power
component and excessive flow is discharged via the pressure-relief valve. This excessive volumetric
flow is discharged from the pressure-relief valve at high pressure, which results in considerable loss
of energy.

Exercise 5:
Unloading a paper machine
Learning objectives
• You will be familiar with the setup and function of a single-acting cylinder, a 2/2-way valve and a
non-return valve.
• You will be able to control a single-acting cylinder.
Problem description
The paper web being discharged from the outlet of a paper machine is wound onto a roll. The roll of paper is
removed by means of an unloading system. The unloading system is operated with the help of hydraulic rams.
Layout
Removal of rolls of paper at the outlet of a paper machine

Exercise 5 – Unloading a paper machine
Description of the process

1. When the hydraulic power unit is switched on, hydraulic fluid delivered by the pump flows directly to
the cylinder. The cylinder is retracted.
2. A normally closed 2/2-way hand lever valve is installed into a branch line which leads directly to the
tank. The cylinder advances when the 2/2-way hand lever valve is actuated. The advancing speed
should be adjustable.
3. A non-return valve is used to assure that no hydraulic fluid is forced back into the pump.
Prerequisites
Screw mount the cylinder in the vertically suspended position to the broad side of the profile column for this
exercise, and load it with the weight. Attach the appropriate cover for the weight. When connecting the
cylinder, be absolutely sure to connect the upper port to the tank.
Assignments
1. Describe the setup and function of a single-acting cylinder.
2. Describe the setup and mode of operation of a 2/2-way hand lever valve.
3. Describe the mode of operation of a non-return valve.
4. Fill in the “meaning or function” of the port designations for valves.
6. Complete the equipment list.
9. Describe the controller’s working sequence.
Visual inspection
Work aids
• Data sheets

1. Setup and function of a single-acting cylinder
Information
The hydraulic cylinder converts hydraulic energy into mechanical energy. It generates motion in a
straight line and is thus known as a linear motor.
1 2 3 4 5 6 7
Single-acting hydraulic cylinder – cutaway view, 1: cylinder bottom, 2: bleed screw, 3: piston rod, 4: cylinder barrel, 5: piston rod guide,
6: piston rod seal, 7: wiper
a) Describe the function of a single-acting cylinder.
b) Name several possible applications for a single-acting cylinder.

2. Setup and mode of operation of a 2/2-way hand lever valve
2/2-way hand lever valve – cutaway view
a) Describe the setup and function of the 2/2-way hand lever valve shown above.
b) Complete the circuit symbol for the 2/2-way hand lever valve (poppet design).
P L
2/2-way hand lever valve – circuit symbol

3. Mode of operation of a non-return valve
Information
Shut-off valves block flow in one direction and allow for free flow in the other. Due to the fact that
shut-off valves need to be absolutely leak-free, they are always laid out as poppet valves and
designed in accordance with the following basic principle:
A sealing element (usually a ball or a cone) is pressed against a corresponding seat. The valve can
be opened by volumetric flow in the flow direction, which lifts the sealing element out of the seat.
If a pressure of p1 is applied to the sealing cone, it is lifted out of the seat thus enabling flow,
assuming the valve is not spring-loaded. Back pressure p2 must be overcome to this end.
Spring-loaded non-return valve – cutaway view, 1: compression spring, 2: sealing cone
– The non-return valve shown here is spring-loaded. How great must pressure p1 be in order for flow to
occur?

4. Identification of valve ports
– Explain the meanings or functions of the designations listed below.
Designation Meaning or function
– Complete the hydraulic circuit diagram.
1Z1
1A1
0V1

Notes
No 2/2-way hand lever valve is included in the equipment set. Use a 4/2-way hand lever valve to set
up the circuit. The unneeded ports at the 4/2-way hand lever valve are plugged with self-sealing
coupling nipples.
No single-acting cylinder is included in the equipment set. Use a double-acting cylinder to set up
the circuit. Connect the port at the piston side to a tank port.
Fully open the one-way flow control valve before dismantling the circuit.
Cylinder, double-acting
9 kg weight for differential cylinder
Pressure gauge
4/2-way hand lever valve
Non-return valve with hose
On-off valve
T-distributor


• Screw mount the cylinder in the vertically suspended position to the broad side of the profile column for
this exercise, and load it with the weight. Attach the appropriate cover for the weight. Be sure to
connect the port at the piston side of the cylinder to the tank.
pressure!

• Fully open one-way flow control valve 1V3.
• Set the pressure-relief valve at the hydraulic power unit to a value of 5 MPa. You can set this pressure
when the cylinder has entered its end-position.

9. Describing the controller sequence
a) Describe the individual steps of the controller sequence.
b) Describe the function of non-return valve 1V1 within the controller.
c) What can be adjusted with the help of one-way flow control valve 1V3?
Notes
Before dismantling the circuit, open one-way flow control valve 1V3 all the way.
When removing non-return valve 1V1, disconnect at the non-return valve side first, and then at the
hose side.


Exercise 6:
Opening a hardening furnace
Learning objectives
• You will be familiar with the setup and function of a 3/2-way valve.
• You will be able to ascertain times, pressures and forces during the advancing and retracting strokes of
a single-acting cylinder.
Problem description
The hood of a hardening furnace needs to be opened by means of a single-acting cylinder. The cylinder is
actuated with a 3/2-way valve. When the hydraulic power unit is switched off, the cylinder must remain in
the end-position. A 9 kg weight must be mounted to the cylinder as a load.
Layout
Hardening furnace hood

Exercise 6 – Opening a hardening furnace

1. When the 3/2-way hand lever valve is actuated, the cylinder is retracted.
2. When the 3/2-way hand lever valve is reset, the cylinder is advanced.
3. Advancing speed is adjustable.
4. A non-return valve is used to assure that no hydraulic fluid is forced back into the pump.
Prerequisites
Screw mount the cylinder in the vertically suspended position to the broad side of the profile column for this
exercise, and load it with the weight. Attach the appropriate cover for the weight. When connecting the
cylinder, be absolutely sure to connect the upper port to the tank.
Assignments
1. Describe the mode of operation of a 3/2-way hand lever valve.
7. Measure traversing pressure during the advancing and retracting strokes.
Visual inspection
Work aids
• Data sheets

1. Mode of operation of a 3/2-way hand lever valve
3/2-way hand lever valve – cutaway view
a) Describe the function of a 3/2-way hand lever valve.
b) Complete the circuit symbol of the 3/2-way hand lever valve.
3/2-way hand lever valve – circuit symbol

– Complete the hydraulic circuit diagram.
1Z1
1A1
0V1
Note
A 4/2-way valve will be used instead of a 3/2-way valve, for which one of the ports will not be
connected. Unneeded ports at the 4/2-way hand lever valve are plugged with self-sealing coupling
nipples.

Pressure gauge
Non-return valve with hose
On-off valve

pressure!



• Close the one-way flow control valve 1V3 completely. Then open it a half turn.
– Describe the individual steps of the controller sequence.

7. Measuring traversing pressure and travel time
Execution
Slowly reverse the 4/2-way hand lever valve. The piston rod in cylinder 1A1 is slowly retracted. The
valve is designed such that the cross-section is not fully opened immediately when the valve is
opened slowly. Hydraulic fluid delivered by the pump initially flows to the cylinder in a throttled
manner for this reason. As soon as the valve is returned to its initial position, the cylinder’s piston
rod is retracted to the lower end position.
a) Measure the necessary values and enter them to the table.
Direction Traversing pressure [MPa] Travel time [s]
Advancing
Retracting
b) Calculate the load pressure which results from the weight.
Characteristic data required for calculation:

Weight load: FG = 90 N
Piston ring surface: APR = 1.2 sq. cm

c) Calculate the cylinder’s retracting and advancing speeds.

Stroke length: s = 200 mm
Pump delivery rate: q = 2 l/min.
Notes
Before dismantling the circuit, open one-way flow control valve 1V3 all the way.
When removing non-return valve 1V1, disconnect at the non-return valve side first, and then at the
hose side.

Exercise 7:
Opening and closing a boiler door
Learning objectives
• You will be familiar with the setup and function of a double-acting cylinder.
• You will be familiar with the setup and function of a 4/2-way valve.
• You will be able to calculate times, pressures and forces during the advancing and retracting strokes of
a double-acting cylinder.
Problem description
A boiler door is opened and closed with a double-acting cylinder. The cylinder is controlled with a
4/2-way valve.
Layout
Boiler

Exercise 7 – Opening and closing a boiler door

1. When the 4/2-way hand lever valve is actuated, the cylinder is advanced.
2. When the 4/2-way hand lever valve is reset, the cylinder is retracted.
Assignments
1. Describe the setup and function of a double-acting cylinder.
2. Describe the mode of operation of a 4/2-way hand lever valve.
7. Measure back pressure, traversing pressure and travel time.
8. Calculate advancing and retracting times and compare your results with the actual measured values.
Visual inspection
Work aids
• Data sheets

1. Setup and function of a double-acting cylinder
Information
In the case of double-acting cylinders, the piston surface and the piston ring surface can both be
pressurised with hydraulic fluid. Consequently they can perform work in both directions.
Double-acting cylinder – circuit symbol and cutaway view
a) Match up the cylinder’s individual components with the corresponding numbers in the graphic.
Component number Component designation
Cylinder barrel
Piston
Piston chamber
Piston rod
Piston rod chamber
Guide tape
Piston rod seal
Wiper seal
Piston seal

b) Describe the function of a double-acting cylinder.
c) Which differences between advancing and retracting the cylinder need to be taken into consideration.
2. Mode of operation of a 4/2-way hand lever valve
A B
P T
4/2-way hand lever valve – circuit symbol and cutaway view

a) Describe the function of the 4/2-way hand lever valve.
b) Think about the consequences of the transitional positions of a 4/2-way hand lever valve.
Transitional position, 4/2-way valve, Transitional position, 4/2-way valve,

positive switching overlap negative switching overlap
c) Name possible applications for 4/2-way hand lever valves.

– Complete the hydraulic circuit diagram for the boiler door.
1A1
1Z1 1Z2
1V1
0V1
Pressure gauge
On-off valve
Equipment list

Equipment list (continued)

pressure!


7. Measuring back pressure, traversing pressure and travel time
Execution
Before measuring pressures and times, the piston rod should be advanced and retracted several
times in order to force out any air which might have flowed into the cylinder’s piston rod chamber
during the last exercises.
– Measure the necessary values and enter them to the table.
Direction Traversing pressure [MPa] Back pressure [MPa] Travel time [s]
Advancing
Retracting

8. Calculating advancing and retracting times
a) Calculate the cylinder’s surface area ratio, advancing speed and advancing time.

Piston surface area: AP = 2.0 sq. cm
Piston ring surface area: APR = 1.2 sq. cm

b) Calculate retracting speed, retracting time, the travel speed ratio, and the travel time ratio.


Exercise 8:
Dimensioning an assembly device
Learning objectives
• You will be able to calculate the forces of a double-acting cylinder.
• You will be able to calculate piston advancing times.
Problem description
Parts are joined by means of an assembly device. The cylinder’s press-fitting force should be calculated
based on the specified data.
In doing so it must be taken into consideration that, although a given press-fitting force is available, a
counterforce acts upon the piston ring side due to resistance in the hydraulic fluid lines and the directional
control valve. Consequently, actually available force is reduced.
Volumetric flow is kept at a constant rate by means of a flow control valve. Together with the cylinder’s
stroke length, this results in travel time for the press-fitting operation.
Layout
Assembly device

Exercise 8 – Dimensioning an assembly device
Assignments
1. Calculate the assembly device’s press-fitting force on the basis of the specified values.
2. Calculate the assembly device’s press-fitting time.
Schematic diagram

1. Calculating press-fitting force
– Calculate piston force, counteracting force and press-fitting force with the help of the specified values.

2. Calculating press-fitting time
– Calculate press-fitting time on the basis of the specified values.

Exercise 9:
Sorting shipping crates
Learning objectives
• You will be able to explain various applications for flow control valves.
• You will be familiar with the setup and function of a one-way flow control valve.
• You will be able to explain the differences between supply and exhaust flow control.
Problem description
Shipping crates are pushed off of one conveyor belt and onto another by means of a double-acting cylinder.
The cylinder is controlled with a 4/2-way hand lever valve. Advancing speed is adjustable and return speed
remains unaffected by this adjustment. Pressure is measured upstream from the cylinder and upstream
from the directional control valve.
Layout
Conveyor belt for shipping crates

Exercise 9 – Sorting shipping crates

1. An open crate stops upon reaching the sorting device.
2. After actuating the 4/2-way hand lever valve, the cylinder’s piston rod advances and pushes the open
crate from conveyor belt 1 to conveyor belt 2.
3. When the 4/2-way hand lever valve is reversed, the cylinder’s piston rod is retracted to the rear end-
position.
Assignments
1. Explain how flow control valves are used.
2. Describe the setup and function of a one-way flow control valve.
8. Measure travel times for the double-acting cylinder.
Visual inspection
Work aids
• Data sheets

1. Use of flow control valves
a) For what purposes are flow control valves used and how is the volumetric flow rate reduced?
b) Into which types are flow control valve subdivided?

2. Setup and function of a one-way flow control valve
A B
One-way flow control valve – circuit symbol and cutaway views
a) Describe the setup of a one-way flow control valve.
b) Describe the function of a one-way flow control valve.

a) Complete the hydraulic circuit diagram for the sorting device. Mount the one-way flow control valve to
the cylinder’s supply port (at the piston side).
1A1
1Z1 1Z2
1V1 A B
P T
0V1
Note
Perform measurements for flow control in the supply line. After completing your measurements,
change the setup.

b) Complete the hydraulic circuit diagram for the sorting device. Mount the one-way flow control valve to
the cylinder’s exhaust port (at the piston rod side).
1A1
1Z1 1Z2
1V1 A B
P T
0V1

Pressure gauge
On-off valve

pressure!
– Select the hose line length such that adequate leeway is available
in order to accommodate changes in length which result from pressure.


• Set the pressure-relief valve at the hydraulic power unit to the operating pressure values specified in
the table.
– Describe the individual steps of the controller sequence.

8. Measuring advancing times for a double-acting cylinder
a) Measure the individual values and enter them to the tables.
Supply flow control

p1Z1 = pressure upstream from the one-way flow control valve
p1Z1 [MPa] Travel time [s]
Exhaust flow control

p1Z1 = operating pressure
p1Z2 = pressure upstream from the one-way flow control valve
p1Z1 [MPa] p1Z2 [MPa] Travel time [s]

b) Evaluate the influence of installing the one-way flow control valve at different locations.

Exercise 10:
Measuring the characteristic curve of a flow control valve
Learning objectives
• You will be familiar with the function and setup of a flow control valve.
• You will be able to record the characteristic curve of a flow control valve.
Problem description
A revolving conveyor chain moves parts through a paint booth. The chain is driven by a hydraulic motor via a
right-angle gear unit. Due to production changeovers, parts of various weight have to be transported
through the paint booth. However, speed must remain constant. It must be determined whether the use a
flow control valve is the most suitable solution.
Layout
Paint booth

Exercise 10 – Measuring the characteristic curve of a flow control valve
Assignments
1. Describe the setup and function of a flow control valve.
6. Measure the volumetric flow rate relative to load and supply pressure.
Visual inspection
Work aids
• Data sheets

1. Setup and function of a flow control valve
2-way flow control valve – cutaway views, 1: regulating throttle (pressure balance), 2: adjustable restrictor
a) Describe the setup and function of a flow control valve.

b) Complete the circuit symbols for the flow control valve.
B B
2-way flow control valve – circuit symbol, left: complete, right: simplified

– Complete the hydraulic circuit diagram for the paint booth.
1Z1 1Z2
1V1 P
1M1
0V1

2-way flow control valve
Pressure gauge
Hydraulic motor
On-off valve
Note

pressure!



• Fully close 2-way flow control valve 1V2, and then open it by about 2 revolutions.
• Fully open pressure-relief valve 1V1.
Note

• Set the pressure-relief valve at the hydraulic power unit to the values specified in the table.
• Set the pressure-relief valve at pressure-relief valve 1V1 to the values specified in the table.
• 2-way flow control valve 1V2 is set to the desired volumetric flow rate of 2 l/min.

6. Measurements
Execution
Load pressure is changed with pressure-relief valve 1V1 in accordance with the specified values.
Pressure-relief valve 1V1 is fully opened for the second set of measurements, and system pressure
is changed with the pressure-relief valve at the hydraulic power unit. The characteristic curve of the
flow control valve for system pressure relative to volumetric flow rate can then be drawn.
a) Measure the values and enter them to the tables.
p1Z1: pressure upstream from the valve

p1Z2: pressure downstream from the valve
qFCV: volumetric flow rate through the 2-way flow control valve
p1Z1 [MPa] p1Z2 [MPa] qFCV [l/min.]
Changing load pressure

p1Z1 [MPa] p1Z2 [MPa] qFCV [l/min.]
Changing supply pressure
b) Draw the characteristic curve.
l/min
q
0
0 1 2 3 4 MPa 5
p

c) Describe your measurement results. Why does the flow control valve demonstrate this type of
performance?

Exercise 11:
Adjusting stroke speed at a hydraulic lift
Learning objectives
• You will be familiar with the setup and function of 4/3-way valves.
• You will be able to evaluate the influences of various mid-position variants.
• You will be able to use a flow control valve to adjust the speed of a drive.
• You will be able to compare circuits with flow control valves in the inlet and the outlet.
Problem description
It will be necessary to set a hydraulic lift for cars to different heights. The hydraulic lift is raised and lowered
with a hydraulic cylinder. Motion must be jerk-free and has to be executed at a steady speed, although the
lift has to hoist a heavy load, namely an automobile. A flow control valve will be used to adjust speed. The
flow control valve should be installed such that no excessively high pressures occur.
Layout
Hydraulic lift

Exercise 11 – Adjusting stroke speed at a hydraulic lift
Assignments
1. Describe the setup and function of 4/3-way valves.
6. Measure the piston rod’s travel speed.
Visual inspection
Work aids
• Data sheets

1. Setup and function of 4/3-way valves
a) Designate the mid-positions of the 4/3 way valves shown below.
1 2 3 4 5
4/3 way valves with various mid-positions – circuit symbols
b) What needs to be observed when using a 4/3-way hand lever valve, mid-position pump recirculation?
A B
P T
4/3-way hand lever valve, mid-position pump recirculation – circuit symbol and cutaway view

c) What needs to be observed when using a 4/3-way hand lever valve, mid-position closed?
A B
P T
4/3-way hand lever valve, mid-position closed – circuit symbol and cutaway view

2. Completing the hydraulic circuit diagram
a) Complete the hydraulic circuit diagram for the hydraulic lift

(4/3-way hand lever valve, mid-position closed, flow control valve in the inlet, pressure-relief valve as a
counter-pressure valve).
1A1
1Z1 1Z2
m
1V3
1V2
1V1 A B
P T
0Z1
0V1

b) Complete the hydraulic circuit diagram for the hydraulic lift

(flow control valve in the outlet).
1A1
1Z1 1Z2
m
1V2
1V1 A B
P T
0Z1
0V1
Note
The configured 2-way flow control valve remains unchanged for the entire series of measurements.

– Complete the equipment list by entering the required number of components and the abbreviations
used to identify them in the circuit diagram to the table below.
Pressure gauge
4/3-way hand lever valve, mid-position closed
2-way flow control valve
1 0V1 On-off valve
5 — 600 mm length of hose
2 0Z1 4-way manifold plate with pressure gauge
1 — Hydraulic power unit

pressure!



• Fully open 2-way flow control valve 1V2.
• Adjust the 2-way flow control valve such that the piston rod advances for approximately 5 seconds. The
2-way flow control valve remains unchanged for the entire series of measurements.
• Set counter pressure to 1 MPa with the help of the pressure-relief valve. This setting is only possible
during advancing cylinder motion.
Note
Before dismantling the circuit, it must be assured that pressure indicated at the pressure gauges
has dropped to zero.

6. Measuring pressure and travel time
a) Flow control valve in the inlet, with counter pressure

Measure the values and enter them to the tables.
The following values are measured:

tadv: cylinder advancing time
p1Z1: cylinder traversing pressure
p1Z2: cylinder back pressure
p0Z1: system pressure
Load and counter pressure p0Z1 [MPa] p1Z1 [MPa] p1Z2 [MPa] tadv [s]
With load, without counter pressure
With load and counter pressure
b) Flow control valve in the outlet

Measure the values and enter them to the tables.

With load

c) Describe your observations.

Exercise 12:
Optimising an embossing machine
Learning objectives
• You will be able to explain the difference between flow control valves and one-way flow control valves
used in the application.
Problem description
Graphic symbols are embossed with a metal foil embossing machine. The foil passes through the embossing
machine during the course of an adjustable cycle time. Downward motion of the embossing punch must be
adapted to feed speed. Rapid traversing must always be used for the return stroke.
A one-way flow control valve is used in order to influence speed. In order to prevent the weight of the
embossing punch from pulling the cylinder’s piston rod out, a pressure-relief valve will be used for counter
pressure. Reversing back and forth between up and down is accomplished by means of a 4/2-way valve.
Layout
Embossing machine

Exercise 12 – Optimising an embossing machine
Prerequisites
Load is simulated with a pressure-relief valve (used as a counter-pressure valve).
Assignments
5. Measure the cylinder’s pressure and advancing speed.
6. Revise the hydraulic circuit diagram.
7. Change the equipment list.
10. Measure the cylinder’s pressure and advancing speed.
11. Evaluate your measurements.
Visual inspection
Work aids
• Data sheets

– Complete the hydraulic circuit diagram for the embossing machine.
1A1
1Z2 1Z3
1V3 P
1V2
1Z1
T
1V1 A B
P T
0Z1
0V1

– Complete the equipment list by entering the required number of components and the abbreviations
used to identify them in the circuit diagram to the table below.
1 1A1 Cylinder, double-acting
3 1Z1, 1Z2, 1Z3 Pressure gauge
1 1V1 4/2-way hand lever valve
1 1V3 Pressure-relief valve
1 0V1 On-off valve
2 — 4-way manifold plate with pressure gauge

pressure!



• Adjust the one-way flow control valve such that the piston rod in cylinder 1A1 advances to the front end-
position over a period of about 5 seconds after 4/2-way hand lever valve 1V1 is reversed. The one-way
flow control valve remains unchanged for the entire series of measurements.
• The pressure value of 1 MPa (10 bar) shown in the “Changing supply pressure” table to which pressure-
relief valve 1V3 must be set, and which can be read at pressure gauge 1Z3, can only be adjusted while
the piston rod is advancing.
• Pressure p1Z1 is adjusted with the pressure relief valve at the hydraulic power unit as soon as the
4/2-way hand lever valve switches through and the piston rod is in the front end-position.
Note

5. Measurements
– Measure the values and enter them to the tables.
p1Z1: pressure upstream from the one-way flow control valve

p1Z2: pressure downstream from the one-way flow control valve
p1Z3: pressure at the counter-pressure valve
p1Z1 [MPa] p1Z2 [MPa] p1Z3 [MPa] tadv [s]
5 1
4 1
3 1
2 1
1 1
5 1
5 2
5 3
5 4
5 5
Changing counter pressure

6. Revising the hydraulic circuit diagram
a) The measurements with the design with one-way flow control valve show a significant increase in
advancing time. How can this behaviour of the control be improved?
The one-way flow control valve is replaced by a 2-way flow control valve.
b) Complete the revised hydraulic circuit diagram for the embossing machine.
1A1
1Z2 1Z3
1V2 1V3 P
T
1Z1
1V1 A B
P T
0Z1
0V1

7. Changing the device list
– Adapt the equipment list to the revised setup by entering the required number of components and the
abbreviations used to identify them in the circuit diagram to the table below.
2 1Z1, 1Z2 Pressure gauge
1 1V3 Pressure-relief valve
1 0V1 On-off valve

pressure!



• Adjust the 2-way flow control valve such that the piston rod in cylinder 1A1 advances to the front end-
position in about 5 seconds after 4/2-way hand lever valve 1V1 is reversed. The flow control valve
remains unchanged for the entire series of measurements.
• The pressure value of 1 MPa (10 bar) shown in the “Changing supply pressure” table to which pressure-
relief valve 1V3 must be set, and which can be read at pressure gauge 1Z3, can only be adjusted while
the piston rod is advancing.
• Pressure p1Z1 is adjusted with the pressure relief valve at the hydraulic power unit as soon as the
4/2-way hand lever valve switches through and the piston rod is in the front end-position.
Note

10. Measurements
p1Z1: pressure upstream from the flow control valve

p1Z2: pressure downstream from the flow control valve
p1Z3: pressure at the counter-pressure valve
5 1
4 1
3 1
2 1
1 1
5 1
5 2
5 3
5 4
5 5
Changing counter pressure

11. Evaluation of the measurements
a) Evaluate your measurement results. Which differences in controller performance did you observe?
b) Why does the controller perform this way?


Exercise 13:
Matching retracting and advancing speed
Learning objectives
• You will be familiar with the setup and mode of operation of a bypass circuit.
• You will be able to explain the influence of the piston’s surface area on pressure, force and travel time.
Problem description
The worktable at a surface grinder is driven by means of a hydraulic cylinder. Due to the fact that speed
should be identical in both directions, the hydraulic controller has to be laid out such that the difference in
volume of the two cylinder chambers is equalised.
A bypass circuit with a 3/2-way valve and a flow control valve for adjusting speed is recommended.
Layout
Surface grinder

Exercise 13 –Matching retracting and advancing speed
Assignments
2. Examine the equipment list.
5. Measure traversing pressure and back pressure, as well as travel time for the advancing and retracting
strokes.
6. Calculate surface area, time and force ratios.
7. Propose solutions for assuring identical advancing and return speeds for cylinders.
Visual inspection
Work aids
• Data sheets

– Complete the hydraulic circuit diagram for the surface grinder.
1A1
1Z1 1Z2
1V2 A B
P T
1V1 B
0Z1
0V1

2. Examining the equipment list
– Check the equipment list for completeness.
1 1V1 2-way flow control valve
1 0V1 On-off valve
1 — T-distributor

pressure!



• Adjust the 2-way flow control valve such that the piston rod in cylinder 1A1 advances over a period of
about 2 seconds after 4/2-way hand lever valve 1V2 is reversed. The 2-way flow control valve remains
unchanged for the entire series of measurements.
Note

5. Measurements

p1Z1: pressure at the piston side of the cylinder
p1Z2: pressure at the piston ring side of the cylinder
Direction Traversing pressure p1Z1 [MPa] Back pressure p1Z2 [MPa] Travel time t [s]
Advancing
Retracting
Values table
6. Calculations
– Calculate the desired values with the specified parameters.

Cylinder dimensions:
Stroke length: s = 0.2 m
a) Surface area ratio
b) Time ratio
c) Force ratio

d) Volumetric flow rate while advancing
– Piston side
– Piston ring side
e) Volumetric flow rate while retracting
– Piston ring side

7. Solutions for identical advance and return stroke speeds
– Think about the conditions under which advance and return stroke speeds are identical for the circuits
shown below.
1A1
1V1 A B
P T
1A1
1V1 A B
P T

Exercise 14:
Securing a cylinder against unintentional retraction
Learning objectives
• You will be familiar with the setup and function of a piloted non-return valve.
• You will be able to use a piloted non-return valve in a controller.
Problem description
A conveyor belt transports metal chips to a bucket. When the bucket is full, its contents are dumped into a
truck. A double-acting cylinder is actuated with a 4/3-way valve to this end. The cylinder’s piston rod is
advanced in the filling position. The piston rod has to be secured against gradual retraction (leakage in the
valve) so that the hydraulic power unit can be switched off during the filling stage.
Layout
Bucket

Exercise 14 – Securing a cylinder against unintentional retraction

1. When the 4/3-way hand lever valve is actuated (flow enabled from port P to port B, and from port A to
port T), the cylinder is advanced.
2. When the 4/3-way hand lever valve is switched to the mid-position, the piston comes to a standstill in
its current position.
3. When the 4/3-way hand lever valve is actuated (flow enabled from port P to port A, and from port B to
port T), the cylinder is retracted.
Assignments
1. Describe the function of a piloted non-return valve.
2. Optimise the hydraulic circuit diagram.
3. Correct the equipment list.
Visual inspection
Work aids
• Data sheets

1. Setup and function of a piloted non-return valve
Piloted non-return valve – cutaway views, left: flow from A to B, right: flow from B to A blocked
a) Describe the function of a piloted non-return valve.
b) Explain how flow is enabled in the blocked direction.
c) Complete the circuit symbol for the piloted non-return valve.
Piloted non-return valve – circuit symbol

d) What must be taken into account when using piloted non-return valves? Consider both circuit diagrams.
m m
1A1 1A1
1V2 B 1V2 B
A X A X
1V1 A B 1V1 A B
P T P T
Piloted non-return valve – circuit diagrams

a) To date, the bucket has been controlled with the depicted circuit diagram. It has been discovered that,
due to the load, the cylinder’s piston rod does not remain in the end-position. Optimise the hydraulic
circuit diagram for the bucket.
1A1
m 1Z1
1V1 A B
P T
0V1

b) Complete the optimised hydraulic circuit diagram for the bucket.
1A1
m 1Z1
1V1 A B
P T
0V1

– Correct and complete the equipment list by entering the required number of components and the
— 9 kg weight for differential cylinder
1Z1 Pressure gauge
1 0V1 On-off valve
1 — T-distributor

pressure!



• Close the one-way flow control valve 1V3 completely. Then open it a half turn.
Note

a) Describe the individual steps of the controller sequence.
b) Which function does one-way flow control valve 1V3 fulfil?


Exercise 15:
Correcting misalignment of a conveyor belt
Learning objectives
• You will be able to use a piloted non-return valve in a controller.
• You will be able to calculate the balance of activities when using 4/3-way valves with different mid-
positions.
Problem description
Parts are transported through a drying oven by means of a steel chain conveyor belt. In order to assure that
the belt does not drop off of the roller, it must be possible to correct misalignment with the help of a belt
tensioner. The steel roller which has to be moved is fixed at one side, and can be moved in the desired
direction by means of a double-acting cylinder at the other side. Hydraulic energy must be continuously
available. When the valve is unactuated, switching to pressure-free pump recirculation should ensue in
order to reduce energy consumption. A counteracting force is applied continuously to the cylinder by the
tensioning station. The piston rod in the tensioning cylinder has to be prevented from gradually retracting
due to hydraulic fluid leakage loss in the directional control valve by means of a piloted non-return valve.
Layout
Steel chain conveyor belt

Exercise 15 – Correcting misalignment of a conveyor belt

1. A 4/2-way hand lever valve can be used to switch to pump recirculation.
Assignments
5. Calculate the balance of activities.
Visual inspection
Work aids
• Data sheets

– Complete the hydraulic circuit diagram for correcting misalignment.
1A1
0V1

– Create an equipment list by entering the required number of components, their designations and the
1 0V1 On-off valve
1 — T-distributor

pressure!


5. Calculating the balance of activities
a) Measure system pressure.
4/3-way hand lever valve Valve symbol System pressure p0Z1 [MPa]
Port P pressurised
1V2 A B
P T
1V1 A B
P T
Port P vented
1V2 A B
P T
1V1 A B
P T

b) Calculate the drive power for the two positions of the 4/2-way hand lever valve. Evaluate the results of
your calculation.
p⋅q
PDR =
η

PDR: required drive power
p: system pressure delivered by the pump: max. 5.0 MPa
q: pump flow rate: 2 l/min. constant
η pump efficiency: approx. 0.7

Exercise 16:
Counter-pressure for closing a bulkhead door
Learning objectives
• You will be familiar with hydraulic restraint of a double-acting cylinder.
• You will be able to compare circuits with and without counter pressure.
• You will be to explain the differences between counter-pressure circuits located between the one-way
flow control valve and the pressure-relief valve.
Problem description
A double-acting cylinder is used to open and close a bulkhead door. Closing should be jerk-free and should
take place at a steady, adjustable speed. Speed is adjusted with a one-way flow control valve.
In order to assure that the heavy door does not pull the piston rod out of the cylinder during the closing
operation, a pressure-relief valve must be used as a counter holder.
Layout
Bulkhead door

Exercise 16 –Counter-pressure for closing a bulkhead door

2. When the 4/2-way hand lever valve is reversed (flow enabled from port P to port B, and from port A to
Assignments
5. Measure advancing time for the double-acting cylinder and evaluate the results.
Visual inspection
Work aids
• Data sheets

– Complete the hydraulic circuit diagram for controlling the bulkhead door
(counter pressure with pressure-relief valve).
1A1
1Z1 1Z2
m
1V1 A B
P T
0Z1
0V1

1 — 9 kg weight for differential cylinder
1 0V1 On-off valve

pressure!



during advancing cylinder motion.
Note

5. Measurement
a) Measure the values and enter them to the table.

With load, without counter pressure
With load and counter pressure
b) Evaluate the measured values.

Exercise 17:
Loading and unloading buckets
Learning objectives
• You will be able to operate double-acting cylinders with changing loads.
Problem description
Buckets are loaded and offloaded to and from trucks by means of double-acting cylinders. The cylinder is
subjected to alternate loading: a pulling load during offloading and a pushing load during loading.
The buckets need to be moved slowly and steadily. The cylinder needs to be hydraulically restrained at both
ends for this reason.
Layout
Bucket

Exercise 17 –Loading and unloading buckets

Assignments
5. Evaluate the circuit setup.
Visual inspection
Work aids
• Data sheets

– Complete the hydraulic circuit diagram for controlling the bucket.
1A1
1Z1 1Z2
0V1

– Create an equipment list by entering the required number of components, their designations and the
1 0V1 On-off valve

pressure!


while the cylinder is in motion.
Note
Open the pressure-relief valve once again before dismantling the circuit.
Make sure that pressure indicated by the pressure gauges has dropped to zero before you start
dismantling the controller.
5. Evaluation
a) Write down your observations.
b) How is hydraulic restraint achieved?


Worksheets Hydraulics Basic Level

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Worksheets Hydraulics Basic Level

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Table of contents

Exercises and work sheets

Exercise 1: Setting up a hydraulic workstation _________________________________________________3

© Festo Didactic 551141 1

2 © Festo Didactic 551141

© Festo Didactic 551141 3

1. Setup and function of a hydro pump

4 Name: __________________________________ Date: ____________ © Festo Didactic 551141

a) Describe the function of the gear pump shown in the figure.

© Festo Didactic 551141 Name: __________________________________ Date: ____________ 5

Hydraulic power unit – circuit symbol

6 Name: __________________________________ Date: ____________ © Festo Didactic 551141

Hydraulic power unit – schematic diagram

Component no. Component (designation)

Vent with air filter

Fill-level indicator, maximum fill-level

Fill-level indicator, minimum fill-level

Motor and pump

© Festo Didactic 551141 Name: __________________________________ Date: ____________ 7

2. Calculating the volumetric flow rate of a hydro pump

– Calculate the volumetric flow rate of a gear pump.

8 Name: __________________________________ Date: ____________ © Festo Didactic 551141

3. Calculating the efficiency of a hydro pump

qeff= Vth ⋅ n ⋅ ηvol

– Calculate the efficiency of a hydro pump.

© Festo Didactic 551141 Name: __________________________________ Date: ____________ 9

4. Selecting a hydraulic power unit

General HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Electrical specifications HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Nominal power 650 W 550 W 550 W

Nominal voltage 230 V 110 V 400 V

Nominal speed 1320 rpm 1680 rpm 1390 rpm

Duty cycle 50% 50% 100%

10 Name: __________________________________ Date: ____________ © Festo Didactic 551141

Hydraulics HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Medium Mineral oil, recommended: 22 cSt (sq. mm / s)

Pump design External gear pump

Geometric delivery rate 1.6 cubic cm 1.6 cubic cm 1.6 cubic cm

Operating pressure 0.5 to 6 MPa (5 to 60 bar)

Pressure gauge indicating range 0 to 10 MPa (0 to 100 bar)

Pressure gauge quality class 1.6

Oil tank capacity Approx. 5 litres Approx. 5 litres Approx. 10 litres

Return filter filtration grade 90 µm

© Festo Didactic 551141 Name: __________________________________ Date: ____________ 11

12 Name: __________________________________ Date: ____________ © Festo Didactic 551141

Two-column hydraulic press

© Festo Didactic 551141 13

14 Name: __________________________________ Date: ____________ © Festo Didactic 551141

1. Types and possible uses of pressure-relief valves

a) What purpose do pressure-relief valves serve?

b) Name various types of pressure-relief valves.

c) Why are pressure-relief valves used in hydraulic systems?

© Festo Didactic 551141 Name: __________________________________ Date: ____________ 15

Commissioning procedure (pump bypass circuit)

Commissioning procedure (circuit with pressure-relief valve)

3. Adjusting pressure-relief valves

Procedure for pump bypass circuit

16 Name: __________________________________ Date: ____________ © Festo Didactic 551141

Procedure for circuit with pressure-relief valve

4. Hydraulic circuit diagram

© Festo Didactic 551141 Name: __________________________________ Date: ____________ 17

18 Name: __________________________________ Date: ____________ © Festo Didactic 551141

5. Creating the equipment list

4 Name: ______________________ Date: © Festo Didactic 551141

© Festo Didactic 551141 Name: ______________________ Date: 5

6 Name: ______________________ Date: © Festo Didactic 551141

© Festo Didactic 551141 Name: ______________________ Date: 7

8 Name: ______________________ Date: © Festo Didactic 551141

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10 Name: ______________________ Date: © Festo Didactic 551141

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12 Name: ______________________ Date: © Festo Didactic 551141

14 Name: ______________________ Date: © Festo Didactic 551141

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16 Name: ______________________ Date: © Festo Didactic 551141

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36 Name: ______________________ Date: © Festo Didactic 551141