BASICS .

OF
HYDRAULIC CIRCUITS

Authors :

P.K. MUKHERJEE S. ILANGO

B.E. (Mech) B.E., PGDIT., MBA.,

FLOWLINES ENGINEERING PVT. LTD.

W-124, 3rd Avenue
Anna Nagar
Madras - 600 040
INDIA
 Second Edition : 1996
PREFACE
© Copyright : Authors
Oil Hydraulics is a fascinating field in engineering. Many of
us take this specialised subject for granted. Indian Universities
generally do not offer specialisation in oil hydraulics in graduate
level or in post graduate level, even.
Generally, it is the international companies involved in oil
hydraulics like Rexroth and Vickers who have brought out
publications to spread knowledge relating to the basics of oil
Price : Rs. 102 hydraulics as well as constructional details of hydraulic elements.
These books cover the principles behind the constructional
details of the hydraulic elements and other components extremely
well. We however find that the basics of hydraulic circuits have not
been given adequate coverage.
The information / knowledge given in this book is prepared
THANKS
and pretested by the experience, we have gained in making oil
hydraulic systems at our factory for varied applications.
We thank M/ s Flowlines Engineering Pvt. Ltd., Madras,
for having sponsored this book Further, the experience gained in training our own engineers
is also used in the book i.e. in making our engineers capable of
- Authors designing the hydraulic circuits to meet different applications of
customers.
The book starts with a set of questions that an application
engineer in oil hydraulics should be aware of, before the design of
hydraulic circuit is even considered.
Step by step procedure is laid out from thereon about circuit
design, chapters are then devoted to designing the circuits for new
applications.
At the end, we have tried to appraise the different problems
that can come up in hydraulic power units so designed. And a chart
is given for trouble shooting.
We sincerely hope that the book serves everyone interested V
Lasertypesetting at:
in learning the basics of hydraulic circuits.
Sri Maruthy Laser Printers, 174, Peters Road, Royapettah, Madras-600 014.
- Authors
 Chapter 1

BASICS OF HYDRAULIC CIRCUITS KNOWING THE QUESTIONS

Knowing the Questions Understanding hvdra^lic circuits and hydraulic powerunAs

starts with the end. In hydraulic circuits design, we must first
understand the actuators, that are normally the end points of a
2. Basic Block-Reservoir and Accesories
hydraulic circuit.

3. A simple Hydraulic Circuit -1 Actuators are nothing but hydraulic cylinders (linear
actuators) or hydraulic motors (rotary actuators).

4. A simple Hydraulic Circuit -2 We must know what the actuator does and we must know
what are the specifications of actuators from the customers, before
starting to design a hydraulic circuit. Designers can study little more
5. Machine Tool Hydraulics and find out where the actuators are used (i.e.) in what kind of
machine.
Hydraulics in Simple Plastic Injection Moulding Machines A standard list of questions to be asked by a hydraulic circuit
designer to end user is presented here. Once we have the answers,
7. A Simple Press Circuit the hydraulic circuit can be designed.
For simplicity sake, let us assume only hydraulic cylinders
. Few more Applications are used and not hydraulic motors;
Most of the users of hydraulic power unit will be in a position
9. This way to Hydraulic Circuits to answer the questions listed here.
List of questions to be asked
10. Common Problems.
1. Is the cylinder single acting or double acting?
2. How many cylinders are used?
11. Standard Graphical Symbols
3. What is the sequence of cylinder movement-one after other
or almost together?
4. What is the function of each cylinder?
 5. What machine all these cylinders go to make?
6. What is the bore size of cylinder?
7. What is the ram size (rod of a hydraulic cylinder) ? Customers
may not know this end hence answer is not an essential one.
8. What is the stroke length of the cylinder?
9. Manual / Solenoid operated Manual
10. What is the force acting on the 1. Clamping - 500 kg
cylinder? 2. Drilling - 300 kg
11. What is the speed of 1. Clamp - 2 meters/mt
movement required 2. Drilling -100mm/min

9. Does the customer require manual/solenoid operated Armed with above information, you have to start working;
(electrically operated or automated) movement? One step at a time
10. What is the force acting on the cylinder?
1. We must know how much or what quantity of fluid is
11. What is the speed of movement required? required to do the work. Hence the first step is to find,-ihe
pump capacity. The capacity is expressed in litres per minute
12. Do they require single speed/double speed or multiple speed
and can be calculated from the following formula.
for the same cylinder, if so what are these speeds:
Q Capacity in lit/min = Area of cylinder
Suppose the customer is better informed and can answer
in sq.cms X
your questions as below:
Velocity of movement
Question Answer of cylinder in cms/minute
1. Single acting / Double acting From the above example
Double acting
2. How many cylinders 2 cylinders i) Q Capacity in lit/min = 78.5 sq.cm (Clamping
cylinder area) X 200
3. Sequence one after other
cms/min clamping
4. Function of each cylinder 1. Clamping speed
2. Drilling 15700 cubic cms/min.
5. What machine all these Drilling Machine 15.7 lit/min
cylinders go to make?
ii) Q Capacity in lit/min = 31.15 sq.cm X l0cros/min
6. Bore size of cylinders 1. Clamping 100 mm dia incase of drilling along area of cylinder X
2. Drilling 63 mm dia drilling speed
= 31.15 cubic cms/min
7. Ram size of cylinders I don't know. Standard
0.31pm
size given by any
reputed manufacturer
1. Since the cylinders have to actuate one after the other, we
8. Stroke length of cylinders 1. Clamp 20 mm can consider a pump having a capacity of 15.71pm or near
2. Drilling - 120 mm about. This will take care of both clamping as well as drilling.

2 3
 2. We know the pump size , what about the working pressure? Generally hydraulic pumps are driven by motors of 1440
We go back to the age old formula (i.e) rpm. Thereis a thumb rule forcalculating the HP of the motor
Force required, given the flow capacity and pressure.
Pressure =
area ower in KW
2.1 Clamping Force Where P = o mg pressure in bar
Clamping pressure
Clamp Cylinder area Kg/cm2
Q = Flow capacity of pump
500K g = 6 in lpm
Clamping pressure .36 Kg/cm2 As per the example,
78.5cm2
P 9.6 Kg/ 2 x 15.7 lpm
2.2 Drilling Force 600
Drilling Pressure 0.25KW600
drill cyl. diameter
0.25
HP 0-346 0.335.0.5 HP
300 Kg
Note 1 :
31.14 cm2
,,Z ,Aar = 1.03 kg/cm2. For sake of simplicity in calculations
9.6 Kg/cm2 we take I bar to be equal to 1 kg/cm.
Note 2:
The maximum working pressure is the higher of the above
two. (i.e) 9.6 Kg/sq.cm
Generally the above formula of-EQ for KW is only a thumb
So far we have found the 600
rule and will not be accurate, especially closer to extremes of the
1. Capacity of the pump ( i.e) 15.71pm ; 16 ^P'^n' characteristic curves of the pump. It is better to refer to selection
2. Max working pressure (i.e) 9.6 Kg/sq.cm curves to decide the exact HP/KW required.

3. We can decide about the reservoir size of power unit. The The above type of calculation, tells us following
Thumb rule is that it should be about 4 times the capacity of 1. Capacity of pump to be chosen
the pump (i.e) the pump capacity say 161pm . The reservoir
size should be 16X4=64lit. 2. H.P. of the motor to be coupled to the pump.

As standard reservoir come in 50 lits, 75 .1its, and 100 fits. 3. Working pressure
We can choose 75 lit capacity reservoir. 4. Size of reservoir
4. What about the Motor HP rating? This is only the beginning, in the design of hydraulic circuit.

4 5
Chapter 2

BASIC BLOCK - RESERVOIR &

ACCESSORIES

BRE AT HER /FILLER

In the last chapter, we have defined the four parameters

required for designing the Hydraulic Circuit. (i.e) Pump
Capacity/Horse Power required to drive the pump/working
pressure and size of the reservoir. The reservoir serves as a store FIGURE- 2 (1 )
for hydraulic oil. The reservoir has certain accessories and these
are explained in this chapter.

The Reservoir in a hydraulic circuit is illustrated in Fig 2 (1)

A breather filler is indicated as 1. and an oil level gauge as

2. The function of the breather fill er is to allow the resen oir to
breathe - (i.e) when the oil from the reservoir is drawn out, it
rushes in to fill in the Qap, vacated by oil and as the oil returns
through return line filter, air is let t.

Breather filler also help us to fill/refill or empty the Reservoir

with oil.

Choose a breather filler of 5 cfm airflow capacity when the

resevoir is less than501its . For over 50lits, 25 cfm airflow capacity
breather filler can be chosen

The oil level indicator (2) indicates the oil level in the FIGURE _2(2)

reservoir. Normally the level indicator comes in sizes indicating the

length - (i.e). 3 inches , or 5 inches or 10 inches. It is fixed close to
the top edge of the reservoir or (say) 100 mm below the top plate
7
of the reservoir.

6
 The hydraulic circuit starts with the reservoir and with
accessories . Please note further addition in building up the circuit-
Figure 2(2)
PR RELIEF VALVE

Please note the addition of pump and the suction strainer. If

the pump is say 61pm the , suction strainer size should be atleast 4
to 5 times the size of the pump . This will reduce cavitation
possibilities of the pump . Further the suction strainer filtration level
is generally 149 microns.
We have added two more to the circuit building up. These
are the relief valve and the return 'line filter. SUCTION STRAINER

The relief valve is selected based on the required working

pressure & flow. We must be in a position to set the working
FIGURE. 2 (3)
pressure with the relief valve and the range has to be chosen
accordingly.
The return line filter is selected on the basis of
P T
jThe volume of flow back to the reservoir. This can be 4 times
the capacity of the pump
Type of mounting on the reservoir (i.e) Tank top or Inline
or tank immersed types
The filtration level is generally 25 microns or 10 microns.
Please refer figure 2(4).
We have added a gauge isolator and pressure gauge in this
figure.
Gauge isolator is to isolate the pressure gauge and only when
the pressure is to be read , we press it (in the case of push to read
gauge isolator) to read the pressure . This helps to prolong the life BASIC BLOCK OF CIRCUIT
of pressure gauge.
FIGURE-2(4)

The pressure gauge is chosen^for twice the working nressnr_e

9
range. Suppose the working pressure is 30 k sq .cm - It is better to
choose 0-60 kg/cm .

8
 For industrial hydraulic power units, it is preferable to Chapter 3
choose 4" dial panel mounted pressure gauge.

In most of the hydraulic circuits the basic block almost

remains same.
So, till we come to circuits including double pumps, this
basic only will be common. Hence to simplify illustrations in the
chapters to follow, we shall just put a rectangular block to indicate
the basic block with its features.
To Summarise
Reservoir size - 4 to 5 times pump capacity
suction Strainer - 4 to 5 times pump Flow capacity
iii. The Basic block of hydraulic power unit comprises of
a. Reservoir
A SIMPLE HYDRAULIC CIRCUIT - 1
Before drawing a simple circuit, we must know that the
circuits can be drawn in conventional manner or using modular
valves. conventional manner means - involving more piping work
(i.e) connecting the individual valve with properly sized tubing. The
better way of doing is using modular valves with manifolds.
Our first attempt here is to make you understand the
conventional way.
We shall illustrate subsequently the same circuit - with
modular valves.

b. Suction Strainer Let us consider a system - where the hydraulic cylinder (say
one number) first pushes a load into the furnance.
c. Pump coupled to electric motor
The basic block, we have understood in the previous chapter.
d. Pr. relief valve From the basic block, we have a P line (pump line) coming out. We
have another end of the circuit (i.e) the T line that gets back to the
e. Return line filter reservoir.

f. Pr. gauge with gauge isolator Refer Figure 3(1)

g. Breather filler The P line is connected to a direction Control (DC) Valve -

a three position DC valve where in its centre position all ports are
h. Level gauge blocked . From the service ports of the DC valve, connection is taken
to A 1 and B 1 ports of a horizontal double acting cylinder.

When the pump is working and solenoid X is energised, oil

gets to the Al port of the cylinder. This would push the piston in
the direction indicated.

10 I 11
 When solenoid Y is energised, the oil from P line gets thro
to B and to B1 of the hydraulic cylinder and the piston moves in
the opposite direction.

At any point in time, if neither X solenoid nor Y solenoid is

A B energised (i.e.) at the neutral position of the DC valve, the piston
does not move.
P (V) CCV_ DIRECTION CC NTROL VALVE

This means, wherever or whichever position you want, you

P T can position the piston by not energising either of the solenoids.
(i.e.) at the neutral position of the DC valve.

At this neutral position all ports are blocked and hence the
oil does not get into the cylinder.

Hope you have understood completely fig 3 (1)

1. If P and T ports are blocked in neutral position, and the pump,

keep running, what is happening to the pressure in the `P'
FIGURE - 3 (1) line ?

2. A and B ports of the valve is also blocked in the neutral

position would this mean that where ever the piston is
stopped, it cannot be moved by manual force?

The pressure in the P line keeps building up as long as the

motor is running which is coupled to the pump. As the
TROL /ALVE WITH
REVERSE CHECK
pressure keeps building up, a stage can come as the oil has
no place to go, the pipe line can burst or the motor can stall-
unless relieved of the pressure.

So we must have the relief valve in the system.

P T - A,B_SERVICE PORTS OF DC VALVE
At Bt_SERVICE
In the begenning before starting the motor/pump, the DC
PORTS OF THE CYLINDER
FIGURE- 3 (2) valve is not energised. This means, in the begenning, itself,
as the motor/pump is started, (Before energising the valve)
12 the `P' line is pressurised. So, when the pump /motor is on, it
starts on load. Is this desirable? It is not:

13

2
 In the neutral position, once the oil is in the pipe lines, the
cylinder cannot be just pushed manually ; is this required for
the application in mind?
Any designer would like the motor (prime mover) to start on
no load.

A B So in such a case, you must choose a DC valve that has a

route (spool configuration) which will allow the oil flow back into
P T
the reservoir in the neutral position.
FIGURE - 3( 3)
FIGURE-3 (4)
Look at the DC valve , spool configuations 3 (3) and 3 (4).

In these types of DC valves, the oil can get back to ` T' line
in neutral position. Hence no load starting of motor is possible just
by choosing a right DC valve configuration . So far we have
discussed oil route that can go to the cylinder and that comes out
through the DC valve.
FLOW CONTROL WITH
REVERSE CHECK VALVE Please refer Figure 3 (2)
Al
We introduced another valve here. This valve as it is shown
B will allow the oil to go through a restriction which is adjustable.
T
Now consider the implications of this flow restrictor (Flow
FIGURE _3(5) control valve with reverse check ) you can reduce the quantity of oil
that will flow through this valve. Result?

The speed of the actuator .during the direction of movement

BASIC BLOCK
indicated comes down - depending on how much is the restriction.
But in the opposite direction it is as free as possible. Why? Because
it can lift the check valve and flow freely and move the piston in
the opposite direction.
FIGURE_3(5)

But, the flow control valve allows only limited volume of oil
14 to flow through . What happens to the oil volume that gets pumped
into the system which is much more.

15
 Well. This excess oil is relieved/blown through the pressure
relief valve. Chapter 4

Remember - all this is applicable only when you consider a

double acting cylinder movement is to be controlled.
A SIMPLE HYDRAULIC CIRCUIT - 2
Suppose the application requires only two positions of the
cylinder without any intennediate stop.
In this case, we can choose a DC valve of two position, as
illustrated in Figure 3(6). Consider an application where a load is to be lifted up (say)
a stacker.
We shall consider a slightly different application in the next
chapter. What are the pit falls-
1. The load should not drop down but stay in desired positions.
2. If the load is lifted and has to be brought down slowly, it
should not come down with a 'thud.' (i.e.) without any
control-if this happens it means that the load is driving the
system.
Now look at the hydraulic circuit in figure 4(1).

Take figure 4(1). A three position, solenoid operated DC

valve with all ports connected (in neutral) is in use.
So, when X is energised, the load is brought down - and
brought down with a thud. (i.e.) The oil takes the path A to Al and
pushed the piston down. Already the load is also acting on the piston
and it comes down fast as the outgoing oil through port B I has a
free passage.
While going up - energise Y and load is lifted up and in the
neutral position, again , the load will drop down - as all ports are
connected.
If a dc valve, where in neutral the P and T lines are connected
in Figure 4(1.1) (A and B blocked), for short duration, the load can
be held in any position (i.e.) when the solenoid valve is not
energised.

16 17
 However, we must remember that all conventional sliding
spool valves allow a leakage (quantity of leakage depends on the
size and pressure differential) and so the load can creep down.
Please refer figure 4(2). The additional valve shown is pilot
operated check valve designated as POC in the figure. This valve
is a poppet design and hence gives zero leak characteristics.

DCV _ D^RECTON CONTROL _A-E The POC valve is located on the B line. The advantage is that
the load can be held in any mid position without the `creeping'
mentioned earlier.
One problem remains:
When solenoid X is energised the cylinder can still come
BASIC BLOCK down more driven by the load and can cause uncontrolled dissent.
Please refer figure 4(3). We have added one more element -
a pressure control (i.e) Counter Balance valve designated as CBV
in the figure.
FIGURE -4(;)
The idea is to control the dissent. This is done by setting the
CBV at a particular pressure. This pressure is set at a value
equivalent to the load divided by the bottom area of the cylinder.
Now the load is counterbalanced and cannot come down due
its own weight unless solenoid X is energised and the set value of
a CBV is exceeded on the ram side of the cylinder.
The CBV has a built in reverse check valve. The advantage
is that when the cylinder is to be lifted up just energise solenoid Y.
FIGURE _4(77) The oil flows into the port B, of the cylinderlifting the reverse check
of the CBV. In furnace gate lifting application, this circuit discussed
can also be employed.
In effect, it means that for such high runaway loads, it is
better to have a CBV in addition to POC - so that control is possible
FIGURE-4(2) in the runaway direction. One more illustration is in the case of a
1 8 vertical drill where at the opening out of the material, the drill tries
a
to break out of control as the load is not there - suddenly. Even in

19
 such applications we must have a CBV in the circuit - to reduce
such undesirable and uncontrollable movements of the drill or the
LOAD cylinder.
Please refer figure 4(4). Suppose further speed control is
I
L required during descent of the cylinder, then we can have a flow
81 control valve, designated as FCV in the figure 4(4). This application
ROC
,BOTTOM AREA
just discussed is also possible with a pump driven by an engine and
with manually operated dc valve. For example, in any lift platform
I CBV
used by airlines for cargo loading.
To summarise, in this chapter, we have seen practical usage
of a pilot operated check valve (POC), counter balance valve (CBV)
and Flow control Valve (FCV).
All these valves are also available in modular form but the
idea is that we understand by illustrating the tine diagram.
FIGURE _4(3) For beginners, (For whom this book is meant), they must
imagine the consequence of not using anyone of the valves in the
LOAD

Al
circuits discussed.
Roc

FIGURE _ 4 (4)

20

21
Chapter 5

MACHINE TOOL HYDRAULICS

Machine tools are generally differentiated into two classes.

(i.e.) special purpose machines (SPM) and general purpose
machines. (GPM)
General purpose machines are those which are standardised
and common like lathes, drilling, milling etc., which are available
off the shelf with standard specifications. The SPM's are tailor BASIC BLOCK

made to suit particular component in large volumes. For example,

an engine manufacturer, may decide to have a special drilling
machine which can gang drill all the holes on the engine head at a
FIGURE-5(1
time.
Let us discuss a few circuits generally used in machine tool
hydraulics.
Clamping Circuit

In machine tools, the job or the tool or the fixture is to be

clamped or held during the machining process.
Please refer fig 5(1)
Here we have two clamping cylinders with one direction
control valve (Two position , solenoid operated , spring offset dcv)
and one pilot operated check valve . The DCV has only one BASIC BLOCK
solenoid . In the de energised position (X side of the valve), the
cylinders are in clamped position . The solenoid Y is to be energised
for declamping operation. What will happen?
Incase the solenoid is energised , the clamp opens (or FIGURE-5(2)
23
releases), and (say ) the job is either removed or being put back.
Imagine in this position , the job is being placed for clamping.

22
Suppose there is a sudden power failure - then immediately, the
spring offset position of the dcv, takes place and the job gets
clamped . Perhaps even before the job is in its place . In all possibility
the hand holding the job also gets clamped , instead of the job - if
the power fails . It is because the pump continues to deliver for few
more moments even after power failure due to inertia.
Please refer figure 5 (2). We have a different type DCV in
FS
place instead of a spring offset solenoid operated dcv. This valve
is known as two position solenoid operated detent type Direction
Control Valve.

The advantage is that this kind of DCV has a mechanical

memory and even in case of power failure, the position of the spool
of dcv does not change-because of a mechanical detent which keeps
the position of a dcv unchanged incase of power failure.

In figure 5(2), you will find wehave two additional elements-

a pressure switch (PS) and a pilot operated check valve (POC)

The function of the POC valve is not to allow leakage of oil

in the clamped position of the cylinder. this means slackening of
the clamp cylinder does not take place. BASIC BLOCK

The function of the pressure switch is that - once the

clamping is done, it is quite likely the function of some other
operation has to take place. We can get an electrical signal from the FIGURE-5(3)

pressure switch once it is incorporated as shown. The pressure

switch converts a pressure reading into an electrical signal - This
electrical signal can be used to trigger some other operation like
energising some other solenoid.

The pressure switch is normally set for a particular limit -

(say)the clamping pressure; Once the pressure switch line reaches
the set clamping pressure limit, a microswitch in the pressure 25
switch, makes a contact and sends an electrical signal to start the
next operation.

24
 Please refer figure 5(3). We have changed the POC valve to
a double pilot operated check valve- what is the significance?

Well. The significance is that by installing a double pilot

operated check valve, we are ensuring the locking of fluid (i.e.)
hermitical sealing on both lines of the actuator. Hence even if there
is an internal leakage (in the cylinder across the piston), the cylinder
remains rock steady.

Please refer figure 5(4).We have one more member to the

family of valves of this circuit. A pressure reducing valve (PRV) is
in place. This PRV reduces the pressure to the clamping circuit as
very often, the job or the tool has to be held positively, firmly and
also delicately. For this purpose, it is not necessary to go upto the
system pressure limits. If we do not have a PRV in place, then the
pressure in the clamping circuit will reach the level of the system
pressure which can distort or deform the job.

Feed circuits in machine tool applications

We must first understand what is usually defined as feed

circuit in hydraulics relating to machine tool applications

Very often, once the job is clamped and the tool is held (say
a drill), the tool is moved rapidly towards the job till tool reaches
the job then (say) the drilling starts (feed), After drilling, the tool is
retracted rapidly.
BASIC BLOCK

The above is common for any machining job,, like turning,

milling etc.,

The process as explained involves two speeds; rapid

approach, and a feed speed (lower speed compared to rapid speed FIGURE-5 (4)

and rapid return)

Dual speed ( feed) with meter in flow control valve

27

Please refer fig. 5(5).

26
 With this kind of circuit, it is possible to get two (dual) speeds
in one direction and one rapid speed in the opposite direction.

Situation 1 : Solenoid X is energised; Flow is through Flow

Control valve FCV to port A2 of the cylinder. As the oil has to go
through the FCV (free flow is not allowed by the check valve of
FCV) the rate of oil flow through part A2 is controlled and hence
n desired reduced feed speed can be obtained in the direction Al I 81 CCV2

indicated. Oil from port B2 flows freely to the tank. This situation
(1) happens when DCV 2 is not energised.

Situation 2 : Solenoid X is energised and DCV2 is also

energised. In DCV2, you will observe that port P1 and B I are
plugged. The purpose of plugging is to make this single solenoid
DCV to function like and on/off valve (or two way valve). In
situation (2) oil flows thro' Ti to Al to A2, thus by passing the
FCV. This means there is no restriction to the rate of flow (as in the
case of situation 1) and hence rapid (fast) speed can be obtained in BASIC BLOCK
the same direction, indicated. On the other part B2, oil flows freely
to the tank.

/ Thus in one direction indicated we are in position to get two

FIGURE-5(5)
s'eds. One for rapid approach and the other slow speed for feed
(machining) purpose.

Situation 3: Now solenoid Y is energised and DCV2 is not

energised. The FCV is by passed and rapid return is possible in the-
opposite direction. This is because oil flow through part A2 comes T
Al
through the check valve lifting the check valve and to the tank.

Situation 4 : Solenoid Y is energised and DCV2 is also

energised. This situation is superfluous as the oil returning from A
part A2 can return freely thro' the check valve of FCV and we are 1 1e
DCV.1 P T
creating an additional free path for the oil from A2 by energising
DCV2. However, if FCV is not having a built in check valve, then
to obtain rapid return, it is necessary to energise DCV2. FIGURE - 5 (6)
29

28

3
Dual speed (feed) with meter out now control valve

Please refer figure 5(6). compared to fig. 5(5), the difference

here is the location of FCV. It is now fixed on the outlet of port B2.
The check valve position is such that the flow coming out of port
B2 has to go through the control orifice of FCV.
Situation 1: Solenoid X of DCV 1 is energised and DCV2 is
not energised. Oil flows freely to port A2. The flow of oil from port
B2 has to come through the control orifice of FCV before going to
the tank line. Hence feed speed is obtained in situation (1) in
direction indicated.
Situation 2: Solenoid X is energised DCV2 is also
energised. Oil flows from P line to Port A2 and oil from B2 flow
freely from B2 to Al to T1. Hence rapid speed in the direction
indicated is possible. FfGURE.5 (7)

Situation 3 : Solenoid Y is energised and DCV 2 is not

energised. Oil flows for movement of ram in the opposite direction.
Oil flow is from P to B. Since port PI and B I are blocked, the oil
flow takes the path through the FCV. It flows lifting the check valve
and onto B2. As the oil flow is not restricted rapid speed is obtained
in the opposite direction to the arrow indicated. The return oil flow
from A2 is free flow to the tank.
Situation 4 : Solenoid Y is energised and DCV2 is also
energised we are creating and additional free path for the oil flow
as in situation 4 of meter in circuit.

The above meter out circuit is especially useful when

runaway loads are to be controlled. For example while the
machining takes place and ends suddenly, the tool may jump
forward. The meter out circuit is useful in minimising such jumps.
FIGURE _5(8)

It must be noted meter out circuits are well accepted and

meter in is not popular. Only for the purpose of theory we have
31
explained the' meter in' concept.

30
Tank line feed control

Please refer figure 5(7). In both meter in and meter out

controls, speed/feed is obtainable only in one direction. But with
tank line feed control, this dual speed is possible in both directions.
To have uniformity of speed, in both directions, in figure
5(7), we have drawn a cylinder with ram on both sides of the piston.
The idea is that the equal area becomes available on both
AREA AVAILABLE
sides and hence same speed is possible in both directions. FULL AREA
REDUCED AREA
AVAILABLE

Situation I : Solenoid X of DCVI is energised oil flows FIGURE _5(9)

through to A 1. DCV2 is not energised. Oil flows from B 1 to tank

line but has to go through the FCV. Hence feed speed is obtained.
Situation 2 : Solenoid X is energised oil flows through to
Al. DCV2 is energised. Oil flow from B 1 to tank line and goes
throughTI to T4. Unrestricted flow and hence full speed is obtained
in this direction.
Section 3 : Solenoid Y is energised and DCV2 is not
energised. Oil flows from P to B I and Al to T. Since DCV2 port
T3 is blocked, oil flows through the FCV and feed speed is obtained.
Situation 4 : Solenoid Y is energised and DCV2 is also
energised. As explained above, free flow through to tank line is
possible and hence rapid speed indirection of line arrow is obtained.
Standard feed block

We have discussed three standard ways of obtaining feed

speeds. But there is a very popular standard way.
Please refer figure 5(8).
This is a standard block manifolded to take on two DCV's,
one FCV and one back pressure valve (pressure control valve) The 33
function of the back pressure valve is essentially to take care of
varying load conditions, jumping of tools or runaway load
conditions. It can be adjusted to reduce the `jump.

32
 One advantage of this standard block is that the FCV is
connected to P line directly unlike in other feed circuit . This means
the response time (of hydrostat in the FCV) of the FCV is much
better. This standard feed block is a meter in circuit and you can
get feed speed in both the directions.

But one point to note:-

0
The area difference on either side of the piston in case
ordinary double acting cylinder is used in the place of double ended
rod. This area difference results in speed difference in either
direction.

Please look at the figure 5(9) for better understanding.

Another feature of the standard feed block is the back

pressure valve. This back pressure valve allows us to fix the back
pressure at different values. For instance, in a light turning
operation a back pressure of 5 bar is sufficient. But in heavy
intermittant milling operation, an increase in back pressure limit
will help rigidity and to have more control over the movement.

Chucking

The emphasis is on rotary chucks which are used in high

production machines like CNC lathes.

Following points to be kept in mind while developing the

BASIC BLOCK
hydraulic circuit.

1. The construction of rotary chuck is such that there will be a

continuous leakage of oil thro rotary joints. Hence there will
be a clamping pressure drop when there is electrical power FIGURE -5 (10),
failure.
35
This has to be taken care of by adding an accumulator backup
in the circuit.

34
 Further because of continuous leakage pilot operated check
valves are not of any use in rotary chuck applications.

2. The chuck sometimes will have to hold slender jobs. This

m eans reduced pressure adjustment is required.

3. Internal and External chucking is to be taken care of by two

position double solenoid detented valves (mechanical
memory type) C ',ING_'EA-

4. Once chucking is achieved a pressure switch sends a signal

for starting the next operation.

Please refer figure 5 (10)

On the basic block, we have an accumulator back up, a

pressure reducing valve. A Direction control valve for selection of
internal/external clamp (DCVI) (Detent, two position), another P7 ; CURE 5',! I1

direction control valve for champing/declamping and the pressure

switches.

In solenoid operated DC valve, (DCV2) the clamping

position is in non energised condition of solenoid. the reason for
choosing such position is explained in the earlier pages. Please
remember what would happen if there is a power failure while
clamping. Hence DCV 2 can also be of detented type.

Even if proper DCV position is chosen (i.e.) the clamping is

done in non energised condition ofthe DCV, there will be a problem.
with the operation of rotary chuck because of leakage.

While the chuck is on (clamp is on and running) and if there

is power failure, there is a pressure loss in the clamping line - due
to drain line of rotary chuck. this can lead to a situation where the
job held gets released from the chuck. If it is an eccentric job that
is held or it is a high speed spindle the sudden release of job can FIGURE - 5(12)

have the effect of a flying saucer hurled at the unsuspecting person

37
nearby. As per the circuit in 5(10) the DCV2 position hold the job

36
and the accumulator backs up the pressure loss till the rotation
ceases - depending on accumulator sizing.
The pressure switches serve the function of sending out
electrical signals for commencing next operations. These electrical
signals are sent once the pressure switch set limits for internal/
external clampings pressure are reached.

Counter Balancing

Let us understand Counter Balancing. In a conventional

machine, (say) vertical boring machine, the boring head weight is
counter balanced with mechanical counter weight running on
pulley or chain as illustrated in figure 5 (11) FIGURE- 5(14

This increases the size and weight of the machine.

In figure 5(12) a compact hydraulic cylinder (single acting) MOVING HEAD

replaces the counter weight. Immediate advantage is the reduction

in size/weight of the machine. The circuit for the same is in 5(13)

For the sake of simplicity and to save paper space, we have

shown the circuit starting from P line. This goes thro a pressure
reducing valve (PRV), a check valve, a relief valve and then to the
input port of the counter balance cylinder.

The pressure selection for reducing valve is computed by the

weight (of the moving head) divided by counter balance cylinder
bore area.

The pressure relief valve setting should be above that of

pressure reducing valve setting to avoid draining of system oil.

The relief valve comes into play only during descent of the
moving head. FIGURE_5(13)

The valve/pump sizing should take care of the rapid ascent

39
of the moving head (and the ram upward movements)

38
 The combination of reducing, check and relief valves are
available as one valve form reputed hydraulic component
manufacturers. (Refer sketch enclosed)
Please refer figure 5 (14)
When the moving head stroke is less as in the case of slant
bed lathe cross slide or the wheel head of a surface grinder, an
accumulator in closed loop is used as a counter balancing device.
T
By close loop, here we mean that there is no external supply
of oil to the counter balance cylinder. This cylinder is directly
connected to an accumulator as shown. The sizing of accumulator
and the cylinder are done in such a way, that at the mid point of the
stroke, the precharge pressure of the accumulator and the counter
balance oil pressure are equal.
- P
Indexing
FIGURE - 5(15)

Indexing can be linear or rotary. In a linear indexing, there

can be two or more defenite positions. The circuit can be as shown
below for a two position indexig table.
The two linear positions are at two ends of the ram travel.
For machining requirement, the end positions must be rigidly held
which is achieved by this circuit - By continuous pressurisation of
indexing cylinder (with the aid of two position DC valve).

Please refer figure 5(15)

This circuit is similar to tank line control of speed discussed
earlier.

We can get dual speeds in both directions by allowing the

now to the tank to go through the FCV. When fast speed is required
DCV2 is also energised.
A two speed control is provided to soften or cushion the end
approach. Alternatively a cushioned cylinder can also be used in FIGURE 5 (16)
place of duel speed control. 41

40
 V
Howeverthe advantage of the secondary speed control is that
we can fix the cushioning as per our requirement, whereas in a
cushioned cylinder the cushioning action is obtained only at the
ends of stroke.
Rotary indexing table in special purpose machines.

When machining has to be done in more than 3 or4 locations,

a rotary indexing table machanism is used.
A plan sketch is shown for understanding.
Please refer figure 5(16)
The rotary indexing table is shown for eight station
I-for loading/unloading
2 to 8 - for various operations such as drilling, tapping, spot
facing, milling, reaming etc.,
In principle the rotation is by a hydraulic motor with a pinion
and an internal bull gear as shown in the sketch.

Please refer figure 5(17) and fig 5(18)

The precise indexing is achieved by face gear mechanism
which also helps in locating and clamping of the rotary table.

Initially the whole indexing table is lifted (declamped),

indexed (rotary movement of hydraulic motor) and lowered
(clamped). Once lowered the face gear mechanism assures precise
!1
LJ location and clamping.

Generally the indexing table rotates little more than the next
location (see fig 5 (18) ) repidly and reverses the direction and
comes back slowly to the intended state.

This is achieved by ahydraulic circuit as shown in fig 5 (18).

FIGURE - 508)
A suggested hydraulic circuit combining the table clamp and
42 idexing is illustrated in fig . attached 5 (19)A.

43
 MOUNTING HOLES

CLAMPING

Al B1

PILOT OPTD
CHECK VALVE

oCV CETOP_ 3

FIGCFE 5(20)

PR GAUGE
CON NECrON/

P T

BASIC BLOCK

CETOP_5
LINE DIAGRAM OF CLAMPING CIRCUIT
FIGUFE - 5 (21)
FIGURE-5(19)

44

45
 Hydraulic circuits - in modular form

CONVENTIONAL LINE MOUNTED VALVE We have so far illustrated hydraulic circuits drawn in
MODULAR STACKABLE VALVE.

conventional manner and perhaps also executed the same way.

By 'Conventional Manner' we mean the piping between he

DPOC valves or the manifolds. But with modular, stackable. sandwich
type double interface valves, we can reduce the piping or plumbing
involved to a great extent.
DCV
The advantage is that it looks neat and reduces leakage,
labour and assembly time.
The limitation is that all valves are not available in modular
form.

P
The best way to understand the reading of modular hydraulic
circuit is to see how we can convert a conventionally drawn circuit
to a modular circuit.

Please refer figure 5(20) and 5(21).

The modular valves, to fecilitate stacking should have two
interface surfaces. One with '0' rings and the other to receive '0'
rings.

Every modular valve willhave four passages(i.e.)P,T,Aand

BASIC BLOCK
B.' Normally the top valve in the stack will be a direction control
valve otherwise a cross over plate or a blanking plate takes the top
position.

A typical hydralic circuit is shown using modular way of

CLAMPING CIRCUIT IN MODULAR CONVENTIONAL FORM representation.
FIGURE _ 5(21) A
Please refer figure 5(21A) which is an equivalent modular
circuit of 5 (19) - clamping circuit.
46

47
CHAPTER 6

CLAMPING INJECTION

HYDRAULICS IN SIMPLE PLASTIC

INJECTION MOULDING MACHINES

The subject of hydraulics in plastic machine application is a

vast one and perhaps a separate book can be written for that pu rpose.
The idea here is to introduce the subject and cover the basic
machines with conventional valves. Further the emphasis will be
on hydraulic circuits and not on the machines.
We shall see simple plastic injection moulding circuits.
The function of hydraulics in these machines are (1) injection
(2) clamping.
Please refercircuit 6(1). We have two cylinders one each for
clamping and for injection. These are operated manually and one
after another. Hence the connection shown is in tandem.
(i.e.) Tank line of one DC valves connected to the pressure
line of the second DC valve. The DC valves used are tandem valves
(i.e.) P&T are connected in neutral position.
The pilot operated check valve (POC) takes care of retaining
clamping pressure while the valve is in neutral position. Since both
DCV's are connected in tandem, in neutral position of both DCV's
the pump output is freely vented to tank.
The circuit has an additional relief valve on the A line of FIGURE -6(1)

injection cylinder. This helps to set the injection pressure of

injection cylinder.
While this circuit is a basic one, further sophistication can be 49

added by having solenoid operated DC valves and a hydraulic

motor drive for injection screw drive etc.

48
 ' For illustration phase see circuit fig 6(2).
The features of the Circuit are :
1. Safety provision for clamping cylinder - unless knob A of
the DC Valve is pushed by a sliding door that will close the
CLAMPING INJECTION SCREW DRIVE
machine, oil, cannot flow thro' this DC valve to the clamping
w
cylinder. This is for the safety of the operators.

WOR CLOSED.
POC FOI 2. Independent pump lines foreach DCVS to injection cylinder,
clamp cylinder and screw drive motor.
3. To reduce heating, an unloding relief valve is provided. This
CLOSING WILL will help the pump to unload during starting, curing etc.,
PRESS VALVE TO
THLS PC6ITION
M

I
L

PLASTIC INJECTION MOULDING M/C.

FIGURE - 6( 2)

50

51
CHAPTER 7

A SIMPLE PRESS CIRCUIT

APPLICATION OF DOUBLE PUMPS

We are considering here a hydraulic press. The applications

of hydraulic press can be many - like deep drawing, forming, POC

shearing, bending, notching, baling, rubber curing etc.,

--LINE OF PILO'.
For the sake of simplicity let us take an example of a curing CEC'!R VALVE

press having M

a. Single cylinder application - single acting - upstroking (i.e.)

gravity return
b. For curing application (i.e) pressure holding for a particular
duration of time.
1. Tonnage or force : 100 tons

2. Day light : 1 meter (The height available between

moving and fixed plates (i.e.) at the fully retracted
position of the cylinder.

3. Speeds : Rapid appraoch and return 2 meters/mt.

Pressing is 0.2 meters/minute - Q
4. Curing time : 20 minutes (Steam curing)

5. Operation : Manual
FIGURE_7(1)

Generally above specifications are sufficient to work out the

hydraulic circuit and select the components/elements of the circuit.
Perhaps the designer on his own can take more interest to know the
53
other details of the press such as the platen weight (for gravity
return), duty cycle etc.,

52
 The steps involved:

1. Find out the working pressure:

At present many of the valves are limited to a working
pressure of 250 bar. Hence we can keep the max working
pressure to 210 bar. (3000psi) and select other parameters.
HP INDICATED BY THE

2. Work out the area of the cylinder: AREA HATCHED

Generally the press manufacturer will give this information.

However the method of working is to be understood.
Load
Working pressure
Full bore area of Hydraulic cylinder ztoKI/cm
P

100T
210 kg/cm2 =
Full bore area of hyd. cylinder FIGURE _ 7 (2)

Area = 476 cm2

This is the full bore area of a cylinder that we can choose.
The cylinder manufacturers follow ISO standards in respect
of bore sizes of hydraulic cylinders (e.g.). The preferred bore size POWER REQLU ED WH'LE
RAPIDLY MOVING THE
can be 40,50,63,100,125, 150, 160, 200, 250 and 300 mm. PLq'EN AT 10 KG'Cm
BUT USING FULL VOLO'-'E
a The full bore area closest to our requirement of 476 cm2 is OF 110 LPM_---

by using 250 mm bore dia cylinder whose full bore area works out POWER REQUIRE WILE
PRESSING AT 210BAR
to 490 Sq.cm. BUT USING ONLY LPM

So we choose 250 mm bore dia cylinder. The rod size can be

left to the choice of the manufacturer of hydraulic cylinders.
3. Work back actual working pressure.
Load
Working pressure
area
FIGURE _7(3)
l00T x 1000 kgs
490 cm 2
= 204 Kg/cm2 55

54
 4. Calculate the flow of the pump required:
Q Flow rate =cylinder bore area x velocity
490 cm 2 x 200 ems/m
1000
= 981pm
100.T UPSTROKING CURING PRESS

The pump which can deliver 100 1pm will be the most
appropriate. (at 1440rpm & on no load). However it is better to
consult the hydraulic product catalogue of standard manufacturer
and choose a pump that meets this requirement. SINGLE ACTIN(-, CV-NDER
25O

We have not considered the pressing speed 0.2 meters/min

in the above calculation, as such as calculation would result in a
lower pump capacity and in turn speed.
cE-cN-ARV RELEF TO PEG
PC'NER CONSUMPTIGN
5. Calculating the electric horse power required:
Standard Industrial drive speed 1440 rpm is assumed here.

The actual horse power required to drive a pump delivering

100 lpm at 1440 and at 210 bar can be obtained from the PR CON?RCL MODU-E

performance curve of any hydraulic pump manufacutures 11G0AR 10 BAR

catalogue. However for theoretical purpose , the thumb rule

calculation is:

PQ _ 210 k?/cm 2 x 100 lpm

H.P. = 600 600

35 KW

= 50 H.P. say (Nearer)

6. Now on to the Circuit,

The circuit is simple and can be understood by the reader. FIGURE - 7 (4)

But the importance is the selection of the pump capacity/motor

HP/Flow and pressure capacity of elements.
Please refer figure 7(1) 57

56
 The DC valve chosen is three position spring centre with all The theoritical HP
ports connected in neutral position. By this we can start the electric l0KK/cm2 X 1001pm PQ
motor on no load and also the POC can normally be connected only rapid closing = 600
600
with such DC valves. these DCV configuration helps the pilot line
of POC to drain in neutral position. As covered earlier the POC 1.6 KW
valve hermetically seals so that the pressure is held throughout the 3 HP
curing process.
For pressing, volume of oil required at 0.2 m/mt
In this case the motor HP theoretically works out to about Q = AxV
50HP. This is nothing but the power absorbed and can be illustrated
in the PQ diagram as follows. = Area of Cylinder x Velocity

Please refer figure 7(2) 490 cm2 x 20 cms/mt

This can be interpreted that throughout the cycle or the
operation we are considering the full pressure and the full volume.
The question is, whether this is required?
In case we consider an option where the platon is moved
rapidly using higher volume of oil but at low pressure and once the
pressing commences, use a higher pressure but with lesser volume
of oil. This is possible with a hi-low circuit using a double pump.
Accordingly the PQ diagram changes as in figure 7(3). When we
consider, a double pump, with high volume and low pressure for
faster approach and for pressing, the claculation is as follows :
Assume the weight of platon and ram as 2 T
The pressure required for lifting = Load
Area
2T x 1000 kg
490 cm 2
(Bore Area of Cylinder)
= 4.08 Kg/cm2
(shown as 10 Kg/cm2 in figure 7 (3)
10 1pm (say)
The HP requi red for pressing and locking will be ; P here
600
will be 210 Kg/cm2 and Q will be 10 lpm.
210x10
(i.e.) 600 = 3.5 KW
= 5 HP (say)
So if we choose a motor of 5 HP, we can run the system and
achieve what we require but of course we would require double
pump. This double pump should be in a position to deliver 1001pm
at 10 kg/cm2 while lifting and start giving 101pm at 210 kg/cm2.
A double pump circuit is shown in figure 7(4). To fecilitate
our requirement of 1001pm at 10 kg/cm2 and later on 101pm at 210
kg/cm2 we must have two relief valves set at two pressure ratings
as above. A standard pressure control module (PCM) is available,
wherein we get initially 100 lpm at 10 kg/cm2. Once pressing
commences, the relief valve on the large volume pumps starts
unloading and the high pressure low volume pumps starts
delivering at a pressure of 210 kg/cm2. So the nett effect is the
reduction in HP from 50 to 5 using a double pump.

58 1 59
Chapter 8

FEW MORE APPLICATIONS

In this chapter we shall look at more applications - such as

table feed drilling, press brake, rubber moulding, thread rolling and
stacker hydraulic circuits. The idea behind choosing the varied
applications is that the reader understands the circuits, and gives
him a feeling that any other circuit similar is easy to understand and Xi;°CJ
to appreciate.
The reader should bear in mind that the more circuits he
learns, and puts to use, it becomes easier for him to think of an
application and try his hand in designing the circuit. -- - --- -

Let us now look at the first application. Please refer fig (8.1)
This is for table feed drilling machine.
Table feed drilling machine application :
Here the table with the component is lifted up rapidly. After
this rapid lift, the feed for drilling, milling etc., takes place. Once
the operation is over, the table comes down rapidly. You look at
fig 8(1), you will observe that all ingredients of a basic block and
similarity with fig 5(6) feed / speed control are there. However,
physically, the machine tool manufacturers opt for a free standing
pumping set and all control values suitably manifolded to be HYDRAULIC CIRCUIT FOR TABLE FEED DRILLING M/C
FIG. P-1
mounted on the column of the drilling machine.
The features here are,
(1) The main DCV has a tandem open centre configuration
whereby pump unloading is achieved. (ie.) the motor stants
on no load when DCV is in neutral position. 61

(2) Two speeds (rapid and feed) are possible in upward direction
and rapid descent in opposite direction are possible.

60
Press brake application

Press brake are used for sheet metal working like bending,
notching, punching etc.,
Please refer figure 8(2)
The customer for this press brake requires a rapid downward
approach, and full tonnage for doing the work and thereafter a rapid
return.
Now look at the two cylinders doing the work. Here
hydraulically, synchronising the movements of both cylinder rams
are not considered. This is achieved by mechanical means.
The features of this circuit are M

I. High low double pumping system to minimise input power

(please refer chapter 7)
2. The main DCV is pilot operated (for handling larger flow)
with tandem open centre configuration (i.e) P&T connected
in neutral position for no load start.
3. Counter balance value (CBV) set for a value just to balance
the. weight. This is to avoid run away load tendencies.
4. A secondary relief value (no 19) limits the maximum lifting
tonnage to the desired value. What happens if this valve is
not provided?
If the valve is not provided their the press works at the full
set pressure of the main high pressure relief valve (i.e) at the end
of the lift stroke.

This also helps in not loading the structure of the machine to

max value at the upward end of the stroke.
Thread rolling application

Please refer figure 8.3 HV RAU_IC CIRCUIT FOR PRESS BRAKE

FIG.. 9.2
Threading on metals can be done in many ways like thread
turning, chasing and thread forming. For mass production normally
63
thread forming is preferred using thread rolling machine.

62
I
 The principle of the thread rolling is that [tic job is kept
between two rotating full profile thread rolls. These !hread rolls are
driven with electric motors. However, hydraulics is used to form
the thread on the job by plunging in the rolls at low feed rate. These
rolls then return at rapid speed. The features are

1. The pump starts at a low pressure (of about 10kgicm2)

keeping the rolls away from each other.
2. The rolls move together synchronised mechanically (not by
hydraulics in this circuit)
3. When the DCV is energised the rolls come towards each
other and towards the job at slow speed (and at higher
pressure meter in circuit)
4. Generally the thread rolling machine the tonnage can be high
compared to the HP. employed. For instance with a 2 HP
motor and with very slow feed corresponding to 40 bar and
with 300 mm bore cylinder we can get the desired high
tonnage.
Rubber moulding and curing application

This hydraulic circuit is employed in a multiple platten,

stream curing up stroking press. Please refer fig 8(4)
In this press upstroking is done by large ram type single
acting cylinder. Lowering of the ram is by gravity.
SCR T ^.cA R^__iNT,
The features are
F:G -8-3-

1. A double pump with hi -low circuit , we have seen earlier is

employed.
2. A special DC value manually operated with decompression
feature is used.
3. The DC value itself is a load holding zero leak value .
4. With 18 inch ram diameter we are able to get load of 350
tons at 220 Bar. 65

64
 a
5. The steam curing takes place in pressed (ie) load holding
condition say for above 20 to 30 minutes This is called as
vulcanising . The DCV can hold the pressure and the pump
is usually stopped to save power.

6. Ram type single acting cylinder is used as we do not require

any power for lowering the plattem . This is achieved by
gravity.

Stacker application

Please refer figure 8.5 This looks more complicated. But

once the circuit is understood, the simplicity of the logic can be
appreciated. In any large processing plant such as for example
cement plant, paper bags are used for packing the cement.

For easy transportation, these cement bags have to be stacked

in an appropriate manner. This is called Pellatisation. This
hydraulic circuit as in figure (8-5) helps us to achieve this objective.

The features are

1. We have two cylinder one for stacking and other for

destacking

2. Here a double purp is employed (ie) two pumps are driven

by a single motor but two different outputs are taken for
independent operation.

Cylinder 1 is for unloading pallet trays to the cruveyor. It is

an independent operation. So an independent pump is used,

Cylinder 2 is for stacker application, where as the load

(cement bags) increases the stacker arm is brought down,
HYDRAULIC CIRCUIT FOR RUBBER CURING M/C
step by step.
FIG.: 6- 4

After the job is done, the empty stacker arm is to be lifted up

rapidly. To achieve this rapid speed, without load, a
67
regenerative circuit is employed.

66

I
 0

For positioning the stacker arm at mid intervals , a POC valve

is used. A counter balance valve preset for maximum load
ackEC pressure assures smooth lowering . The proportional valve is
_Y LIP.,F?2_L
programmed for acceleration and deceleration v ith varying
load conditions.
3. We come across a new feature -- a preportional pressure an('
flow control valve combination is used as a load sensing
system. ( 9) for smooth acceleration and declaration with
varying load conditions. In addition to proportional control.
PLCs ( Program able logic controls) are used for different
programming for different sizes of cement bags . (loads)
With PLC and proportional controls, smooth movement is
taken care of.
The number of hydraulic circuits can be limited only by
imagination acid by actual requirements.
There can he many solutions to one reuuirements and t`ae
near optimum circuit designing Lames b years of oxposure
.nd experience

`1YOPAULIC C'RCUIT FOP ST.;CKER

'IG: 6-5 -

08

b:?
CHAPTER 9

THIS WAY TO HYDRAULIC CIRCUITS

'C00 KG

yy_ SDP PCPT

A .CAD OF 1OCKG
This book is meant to give basic knowledge on designing a ON1CS0 CM 7!a .ISTCN
PISTON
hydraulic circuit. But a hydraulic circuit designer should have solid
10SO CM
information base about the hydraulic elements, their symbols,
i
functions and certain fundamentals. The reason that this chapter
comes almost at the end of the book is that we have assumed the - CONS NEJ

readers have a working knowledge of hydraulics principles,

theories and the functional aspects of hydraulic elements. However PRES-:PE
L--- DD7E'_CPES
our thinking is also to show the way to the building of hydraulic
circuits. FIG_ 9.1

It is possible to write a separate book on the principles,

constructions, functions of oil hydraulics and the elements used.
But we are going to make an attempt to give a concise account of
these fewer aspects.
9.1 The symbols :

The Hydraulic circuit designer should be thorough with the

symbols and we have reproduced these symbols in the annexure.
Qt I
9.2 Pascals Law

This is a simple law and means this :

Pressure applied on a confined fluid is transmitted
LONG PIPE LINE
undiminished in all directions and acts with equal force on equal
areas and at right angles to them.
FIG- 9 2
How is this applicable to everyday usage of hydraulics`!
If we apply a small force on a small area we can get it
71
transmitted to larger area and you will get higher force available to

70
 work foryou (of course it should be a force on confined fluid) please
refer figure 9.1
9.3 Positive displacement pumps

We have come across, in cur daily living domestic pump sets

- which are centrifugal pumps. -=---1 L-_ 1-- - --^
How are the pumps used in hydraulic power units different THE PRESSURE
-_-- __ PRESSURE HERE

HERE - --- - _ - `--- -- - THEN NO FLOW

from this centrifugal pumps. The differences are,
1. Most pumps used in hydraulic systems are positive
displacement pumps FIGURE-9 3 (1 )

2. The pump output is normally constant irrespective of the

pressure.
3. The outlet is positively sealed from the inlet, so that whatever
gets into the pump is forced out through the outlet port. AN WCREASE _ - .
-- - 'IE OIL TO F^_OW -- - TO THIS PLACE
PRESSURE e
Th,.re is a misconception or shall we say a wrong expression HERE CASES TORO THE ORIFICE

gzrerally voiced by many users of oil hydraulic systems.

They come with a complaint, at times, that the pump does 'HE PRESSURE DROP_-_ 7
FIGURE-9 3 (2)
not develop pressure. We must understand very clearly that the
pumps here, create only flow; and not pressure. The pressure in the
system is due to the resistance to the flow. The resistance or the
pressure is created when the hydraulic oil has to flow thro' pipes
A_TND R ARE EGUAL SIZE CYL'.NDERS
(pipe friction), thro' bends and joints and thro' orifices of the ' CS A_IS_ IOC.-?,___ SAD _N
LOA[_
valves; and from the load of an actuator. You will come across 57C D[I L EST TAKE
THE PATH OP LEAST RESISTANT E(,e )
pump specification of manufactures that the max. pressure of the CIL WILL ALOW TO_A __F_RST. UFT

pump is say 160 bar. This only means that the pump can withstand LIFT ^ IULLY AND THEN WILL
FLOW T0 B
a pressure of 160 bar and not that it creates a pressure of 160 bar. PUMP

If this complaint is that the pump is net developing pressure,

then the user is trying to tell us that with his system. he is net able
to get the work done. If the problem is with the pumps internals, it
can be because the pump is womout and the sealing between suction FIGURE_9-4

and delivery is no forger effective. But the problem can be

anywhere along the lire from suction strainer to the cylinder. We 73

shall discuss this subject separately.

72

N
9.4 Pressure drops and orifices :

Any Hydraulic power unit has flow of oil thro' Orifices (Any
valve has an orifice and the more the valves are in a power unit, the FRICTION REDJCES THE
HEAD AT SUCCEEDING
greater is the emphasis on pressure drops. POINTS EXCEPT WHERE

Even on a normal flow of fluid through a long pipe line, there

will be a pressure drop. Refer figure 9.2.
LARGE? PIPE REDUCES
The pressure drop is because of the friction of the pipe. VELOOCT-- -, THE P'.-0 "
AND PRESSURE INCREASE

As the oil, flows thro' the pipe, fittings, manifolds and

valves, there is a reduction in the final pressure available to the FIGURE-9 5

actuator. It is not possible to avoid the pressure drop. However by

proper sizing of the pipe and the valves it is possible to reduce this
pressure drop. Energy lost due to pressure drop is converted to heat.
To reduce this pressure drop, proper selection of valve and piping
are important.
A'.,GE aRESSURE
The heat produced due to energy lost results in viscosity
" GAUGE PRESSURE
reduction of oil. This reduction of viscosity results in leakages, loss EKG CIO G:^1 CRFS A?41 PP

;.UGE PRESSURE
in lubricity and cause wear and tear and inefficiency.
A`vr'SL I, rt

Then, can we use the orifices to adjust speed?

Yes. This is the right question. To tune the system for speeds, ABSOLUTE PRESSURE

we can open and close the restrictions. 760r 10M!s '1 27MIs
IN HG VACUMN SCALE. WATERCCWMN 0IL COLUMN
BAROMETER SCALE
9.5 Path of Least Resistance VACUMN CAI;GES
FIGURE 9 6
VACUMN I^N7-'S RANGE

Fluid flows through the path of least resistance when there ATMOSPHERIC PRESSURE = 1.03 AC;CM
BAR
is more than one possible flow path in the system. please refer figure
76CmmCF HG
9.4 '-0 "E'ERS GF WATER COLUMN
1127 METERS CF OIL COLUMN

A and B are equal size cylinders load on A 100 Kg. Load on GAUGE PRESSURE IN BG/CM2+1.03 NO'CM ABSOUJTE PRESSURE IN NGrrCM

B is 500 Kg.

Oil will first take the path of least resistance (ie) oil will flow
to A first lift it fully, and then will flow to B. 75

74
9.b Bernoulli's Principle of oil flow'

Understanding Bernoulli's principle is an important factor in

the design of hydraulic valves. In such valves the oil path sizes
change and Bernoulli's principle tells us, what happens if there is ATMOSPHERIC PRESSURE
PUSHES MERCURY IN TO
an increase or decrease in the size cf the oil path. We have earlier THE TUOE_
in the chapter seen the changes in pressure drops across orifices. MERCURY RISES BY 760 mm

Here we shall discuss the path ways.

We must first understand that the fluid in a working system
contains energy (ie;i Kinetic energy by virtue of velocity and its
weight and potential energy in the form of pressure.
FfGURE.97( Ii
Bern-)ulli's principle states that if the flow rate is constant,
the sums of the kinetic energy and the pressure energy at various
points in a system must be constant. Therefore, if the kinetic energy
decreases, it results in an increase in the pressure energy.
A
Please refer figure 9.5
ST_MO_SP_HERIC PRESSURE
As in figure 9.5, when the Cross Sectional area of a flow path PUSHES_ODU iN TO THE
PJMP Li IE
increases, the decrease in Kinetic energy (velocity) iesuits in
coirespond-iig increase of pressure energy as shower by a higher
heat;
4.7 The effects of pressure
GU^F.9 ! 2)
In a hydraulic power unit, pressure is generated by resistance
to the flow of oil and mainly by the load. In other words pressure
is proportional to the work load, and a pressure guage reading

TI
indicates generally the work load.
In many places, the user of a hydraulic power unlit ignores
tLe importance of apressure guage and normally the pressure guage
cf a system does not work.
Only when there is a problem in the power unit, the
importance of the pressure guage will be realised.
The pressure guage normally ignores atmospheric pressure.
(ie) The standard guage points to zero at atmospheric pressure.

76
 9.7.1 Atmospheric pressure :
It is the weight of air, atmosphere outside, that exists. We are
used to it, so we do not feel it.
This is actually the weight of air in the atmosphere that acts
on every square centimeter.
In terms of value, this atmospheric pressure works out to 1.03
Kg/cm2. Please refer figure 9.6
* One atmospheric Pressure = 1.03 kg/cm2
1. BAR
760 mm of Hg
10 meter of water column
11.27 meter of oil column
* Guage pressure in Kg/cm2 + 1.03 Kg/cm2 = Absolute
pressure in kg/cm2
Most of the hydraulic oil pumps used are capable of creating
only a partial vacuum. Air pressure on the oil in the reservoir pushes
oil up the suction line. As the pump cannot suck the oil all the way
through, the height of pump installation above oil level is a matter
of concern.
Pumps available today can normally create a partial vacumn•
equivalent to about 150 mm of mercury which is one fifth on the
vacumn scale. In terms of oil height one fifth of the oil height works
out to about 2.25 metres. This is in ideal conditions. But when we
talk of practicalities, considering the suction pipe and fitting losses,
when suction strainer is also in use, we can consider only about one
metre or there about.
Therefore a hydraulic pump with adequately sized inlet pipe
and suction strainer should never be mounted higher than one meter
above the oil level.
78
For information the suction pipes are selected for a
maximum oil velocity of 1 meter per second.
Cavitation and aeration in a pump
A pump with adequate suction characteristics (ability to
increase partial vacumn to the extent of one fifth in vacumn scale
(ie) six inches of Hg or 150 mm of Hg)-can be installed in within
one meter height of oil level. If the pump does not have such
characteristics, the pumps can be mounted below the oil level.
We must remember here that for every foot of oil, oil creates
a static head pressure of 0.4 psi.
As we try to locate the pumps below the oil level, for each
foot, we add a positive pressure of 0.4 psi available to the inlet of
the pump.
Under these conditions the pressure losses due to strainer,
suction line and fittings still to be substracted from the total
pressure available at the inlet conditions.
In a partial Vacumn Condition, when the pump is located
above the oil level, then this less than atmospheric pressure acts on
the oil.
The mineral based hydraulic oil, which we use, contain about
8 to 9% of dissolved air. Now, when the `less than atmospheric
pressure' acts on the oil, the air in the oil expands and becomes a
higher percentage of volume. This means, more air in oil gets into
the pump chamber. At the outlet of the pump is the system pressure
which is considerably more. The air bubbles in the oil will now
collapse at considerable pressure in the pumping chamber. This
rapid collapsing of air bubbles results in rapid energy losses in the
form of heat and noise. This heat can result in combustion of oil
leading to carbonisation.
When the pressure gets low on the suction side, it can also
result in vaporisation of oil, the combined effect of all this is know
as cavitation effects.
1 79
Chapter 10

TROUBLE SHOOTING

It is only appropriate that a person who designs the circuits,

knows what can go wrong with the power units.
In the pages to follow we are giving charts descrih,ng
common problems and remedies that can solve these problems.
REMEDY : d
These charts also will be very useful for maintanance
engineers using hydraulic power units in their shops.
Most of the problems in hydraulic machinary are relates; to
oil contamination. The suction strainer can clog du,; to
contamination. This can result in cavitation of pump.
Contamination can also make th,, valve sticky. The DC valve 'oils
can bum due to sticky valves.
Anotherpoint is that we should ensure oil and airdo not mix.
They are not made for each other.
A loose suction joint can allow system toaerate causing
severe pump noise and jerky movement of actuator.
A word of Caution

We have come across problems that are not associated with

power units but are machine problems or relating to electrical
circuits. Therefore it is essential that before trouble shooting, the
problem is identified to be relating the hydraulics side of he
machine.

80
CHART I - REMEDIES

a. Any or all of the following : Replace dirtyfilters - Wash

2
strainers in solvent compatible with system fluid - Clean
0 a
clogged inlet line - Clean reservoir breather vent - Change I-
0
system fluid - Change to proper pump drive motor speed - 0 0
Overhaul or replace superchange pump - Fluid may be too W
3
0
O
W
W
0 W
cold Z w a.
a
O 0
0
b. Any or all of the following: Tighten leaky inlet connections Z

- Fill reservoir to proper level (with rare exception all return n

lines should be below fluid level in reservoir) - Bleed air from

system - Replace pump shaft seal (and shalft if worn at seal z
journal) o 0 Z
U

c. Align unit and check condition of seals, bearings and U LU

W
coupling 0
z
0
d. Install pressure guage and adjust to correct pressure
N

e. Overhaul or replace
I
CHART II - REMEDIES 0 0
0
W

a. Any or all of the following : Replace dirty filters - Clean

W
UI 2
W
U
clogged inlet line - Clean reservoir breather vent - Change W

system fluid - Change to proper pump drive motor speed - UI

3

Overhaul or replace supercharge pump

b. Any or all of the following: Tighten leaky inlet connections

- Fill reservoir to proper level (with rare exception all return O
C!
lines should be below fluid level in reservoir) - Bleed air from U
0 0
W W W
system - Replace pump shaft seal (and shaft if worn at seal 0 3
w
M 0

H o a 0
journal) U- Z
IW

c. Align unit and check condition of seals and bearings Locate

and correct mechanical binding - Check for work load in
excess of circuit design. 83

82
 d. Install pressure guage and adjust io correct pressure (Keep
atleast 125 PSI difference between valve settings)
CHART - III
e. Overhaul replace
HNCORF,ECT FLOW

f. Change filters and also system fluid if of improper viscosity-

A S C
Fill reservoir to proper level
ENO FLOW LOW FLOW L EXCESSIVE FLOW I
g. Clean cooler and/or cooler strainer - Replace cooler control
valve - Repair or replace cooler. PUMP NOT RECEIVING
FLUID I
P FLCV CONTROL SET
TOO LOW
FLOW CONTROL SET
TO HIGH

REMEDY a REMEDY d_ REM E!'Y d

I YOKE ACTUATING
CHART III - REMEDIES PJHP CRIVE MOTOR RELIEF OR UNLOAD:NG
V V SET TOO LOW DEVICE INOPERATIVE
NOT CPERATIN G
(VARWBLF ISPLAC MEN''
PUMPS)

REMEDY c REMEDY e ar f REMEDY

a. Any or all of the following : Replace dirty filters - Clean
clogged inlet line - Clean reservoir breather vent - Fill P PDRIVE MOTOR EXTERNAL LEAX IN IMPROPER SIZE
SYSTEM PUMP USED 'OR i
P RNING IN WRONG
reservoir - proper level - Overhaul or replace supercharge DIRECTION REPLACEMENT
pump REMEDY g REMEDY REMEDY 'I

b. Tighten leaky connections - Bleed air from system DIRECTION CONTROL YOKE ACTUATING RPM OF PUMP DRIVE
SET IN WRONG DEVICE INOPERATIVE
MOTOR INCORRECT
POSITION (VARIABLE DISPLACEMENT
c. Check for damaged pump or pump drive - replace and align PUMPS)
REMEDY h
coupling REMEDY :f REMEDY

d. Check for damaged pump or pump drive - replace and align ENTIRE FLOW PASSING RPM OF PUMP
OVER RELIEF VALVE DRIVE MOTOR
coupling INCORRECT

REMEDY d REMEDY h
d. Adjust
DAMAGED PUMP WORN. PUMP
e. Overhaul or replace V V, MOTOR, CYLINDER
OR OTHER COMPONENT

f. Check position of manually operated controls - check REMEDY c REMEDY : e

electrical circuit on solenoid operated controls - Repair or

IMPROPERLY
replace pilot pressure pump ASSEMBLED PUMF

g. Reverse rotation REMEDY e

h. Replace with correct unit

84
 CHART - V

FAULTY OPERATION

A c D

in NO SLOW ERRATIC EXCESSIVE SPEED

MOVEMENT MOVEMENT MOVEMENT OR MOVEMENT

NO FOLW OR LOW FLOW ERRATIC EXCESSIVE FLOW

PRESSURE PRESSURE
REMEDY : SEE REMEDY : SEE REMEDY : SEE REMEDY : SEE
CHART III COL A CHART Ill COL 8 CHART IV COL C CHART III COL C

w LIMIT OR FLUID VISCOSITY FEED BACK

AIR IN FLUID
U ^
SEQUENCE DEVICE TOO HIGH TRANSDUCER
z Q u (MECHANICAL REMEDY : SEE MALFUNCTIONING
u ELECTRICAL OR REMEDY : a
0 o r nro HYDRAULIC) CHART 1 REMEDY e
U
z < o O J INOPERATIVE OR
z 5 W MISADJUSTED
cr fe
3 REMEDY e
O U
U O

MECHANICAL INSUFFICIENT NO LUBRICATION ^ JUSTED

MISAD I
BIND CONTROL PRESSURE OF M/C WAYS OR MALFUNCTIONING(
FOR VV OR LINKAGE I SERVO AMPLIFIER
REMEDY b REMEDY : SEE REMEDY : g REMEDY : ..
K CHART IV I
U,
Vf 0

NO COMMAND NO LUBRICATION ERRATIC COMMAND OVER-RIDING

SIGNAL TO SERVO OF MACHINE SIGNAL WORK LOAD
AMPLIFIER WAYS OR LINKAGE
REMEDY f REMEDY g REMEDY f REMEDY h

INOPERATIVE OR MISADJUSTED OR MISADJUSTED OR

MISADJUSTED MALFUNCTIONING MALFUNCTIONING
SERVO AMPLIFIER SERVO AMPLIFIER SERVO AMPLIFIER
REMEDY c REMEDY : c REMEDY c

3 w J
INOPERATIVE STICKING SERVO I MALFUNCTIONING
O ..O SERVO V V VALVE (FEEDBACK TRANSDUCER
a I- HG' ° REMEDY c REMEDY : d REMEDY
Z uOf
O W =

I
U
WORN OR DAMAGED WORN OR DAMAGED STICKING SERVO VALVE
CYLINDER OR CYLINDER OR
MOTOR MOTOR REMEDY d
REMEDY e REMEDY : e
WORK OR DAMAGED
CYLINDER OR MOTOR
86 REMEDY : e
87
CHART IV - REMEDIES
STANDARD GRAPHICAL S''MBOLS

a. Replace dirty filters and system fluid

b. Tighten leaky connections (fill reservoir to proper love; and

bleed air from system)

c. Check gas valve for leakage Charge to correct pressure

Overhaul if defective

d. Adjust

C. Overhaul or replacc

CHART V - REMEDIES

a. fluid may be too cold or sl.ou:d be changed to clean fluid of

';orrcct viscosity

b. Locate hind and repair

c. Adjust, repair, or replace

d. Clean and adjustor replace - Check condition of system fluid

and filters

e. Overhaul or replace

f. Repair command console or interconnecting wires

g. Lubricate

h. Adjust, repair, or replace counterbalance valve.

88
 MULTIPLE FLOW PATHS
RESERVOIR VENTED (ARROW SHOWS FLOW FTFMlEllTURE AND
l-----] DIRECTION) PR COMPENSATED SOLENOID f1
FLOW CONTROL WITH
INTEGRAL CHECK
I
PRESSUR GAUGE UNLOADING VALVE,
0 INTERNAL DRAIN,
SOLENOID CONTROLLED
REMOTELY OPERATED I DIRECTIONAL VALVE .
PILOT PRESSURE
TWO POSITION, THREE
OPERATED
CONNECTION
ACCUMULATOR
4
GAS CHARGED
DECELERATION VALVE,
DIRECTIONAL VALVE,
NORMALLY OPEN SPRING
THREE POSITION,FOUR
CONNECTION

FALTER OR STRAINER VALVE, INFINITE

SEQUENCE VALVE POSITIONING (INDICATED
BY HORIZANTAL BARS)
DIRECTLY OPERATED
PROPORTIONAL CONTROL
EXTERNAL DRAIN

PRESSURE SWITCH
PRESSURE COMPENSATOR,

PR. REDUCING VALVE

CHECK VALVE

DETENT
--
MANUAL SHUT OFF
VALVE
COUNTER BALANCE
VALVE WITH INTEGRAL
VALVE , MAXIMUM CHECK
i LEVER
PRESSURE (RELIEF)

90