HYDRAULIC CIRCUITS

HYDRAULIC CIRCUITS
SINGLE ACTING
CYLINDER CIRCUIT
DOUBLE ACTING
CYLINDER CIRCUIT
RECIPROCATING
CIRCUIT
REGENERATIVE
CIRCUIT
SEQUENCING CIRCUIT
SYNCHRONISING
CIRCUIT

ACCUMULATOR
CIRCUITS
SAFETY SIRCUITS
PUNCHING PRESS
DRILLING AND
CLAMPING

SINGLE ACTING CYLINDER

CIRCUIT
Control of a single acting
hydraulic cylinder

SINGLE ACTING CYLINDER

CIRCUIT

It has a reservoir, pump, two position- three way manual operated

direction control valve, a pressure relief valve and a single acting
cylinder.

In its normal position, the fluid is diverted back to the tank through
the pressure relief valve.

When the direction control valve is manually pushed to left envelop,

flow enters the piston side of the single acting cylinder.

At the end of extension stroke, DCV is pushed to right envelop

resulting in the pump flow diverted through the PRV to the tank.

The fluid in the cylinder is pushed by the spring on the rod side to
retract and the flow goes to the tank

DOUBLE ACTING CYLINDER

CIRCUIT
Control of a double-acting hydraulic cylinder
F Load
A

B
T

DOUBLE ACTING CYLINDER

CIRCUIT
It has a reservoir, a pump, a pressure relief valve,
manual operated three position four way DCV (tandem
position), and a double acting cylinder
In its spring centered position, the cylinders are
hydraulically locked and the flow without any increase in
pressure is diverted back to the tank (advantage of
tandem position)
When shifted to left envelop position of the DCV, flow
enters the piston side of the cylinder and extension
stroke takes place against the load

DOUBLE ACTING CYLINDER

CIRCUIT

At the end of extension stroke, the DCV can be shifted to the right
envelop in which case the flow is directed to the rod side of the
actuator and retraction takes place.

In the double acting cylinder both extension and retraction is by the

fluid.

The extension of the cylinder is slow as they act against the load but
can carry large load as the area on the piston side is more

The retraction in double acting cylinder is fast as the area on the rod
side is less and the same pump flow enters the side.

At the end of extension and return strokes if the flow is not stopped
there is increase in pressure and flow is diverted through the PRV.

RECIPROCATION CIRCUIT

RECIPROCATING CIRCUIT
This circuit has a reservoir, a pump, a pressure relief
valve, pilot operated spring centered four way three
position DCV, pair of Sequence Valves, a pair of check
valves, and a double acting cylinder.
In its neutral position, the pump flow is diverted through
the PRV at high pressure.
When the DCV is shifted to any position, the pump flow
is diverted either to rod side or piston side

RECIPROCATING CIRCUIT
If flow enters the piston side, then extension takes place
and at the end of the stroke, the pressure is increased
and the flow is diverted through the sequence valve
which shift the DCV to its left envelop.
In this position, the flow is diverted to the rod side of the
actuator and retraction occurs. At its end similarly the
increase in pressure is sensed by the sequence valve
and shifts the DCV to its right envelop
Thus the continuous reciprocation takes place as long
the flow is stopped.

RECIPROCATING CIRCUIT
The check valves and their corresponding
pilot line prevent shifting of the four way
valve until particular stroke is completed.
The check valves are needed to allow pilot
oil to leave either end of the DCV while
pilot pressure is applied to the opposite
end which will permit the shifting of the
spool of the DCV

REGENERATIVE CIRCUIT
Regenerative circuit

F Load
Blocked

REGENERATIVE CIRCUIT
This circuit is used to speed up the extending speed of
the double acting actuator.
In this circuit the pipelines to the cylinder are connected
in parallel and one of the ports of the DCV is blocked.
In the left envelop of the DCV, the flow from the pump
and the flow from the rod side (regeneration) joins and
this results in the increased speed of extension.
When shifted to the right envelop of the DCV, the flow
bypasses the DCV and enters the rod side and the fluid in
the piston side drains through the DCV.

REGENERATIVE CIRCUIT
Total flow to the piston side
QT=QP+QR
Pump Flow QP=QT-QR
Total flow rate AP X VP ext
i.e. (area of piston) X (speed of extension)
Regenerative flow rate = (AP AR) X VPext
Therefore, QP= AP X VP ext- (AP AR) X VPext
VP ext = QP/ AR (this gives the large velocity of
extension)

REGENERATIVE CIRCUIT

Ratio of Extending and Retracting Speeds

Retracting Speed VP ret= QP/ AP-AR

VP ext/ VP ret= (QP/ AR )/ QP/ AP-AR

= AP-AR/ AR
= AP/AR-1
When Piston area= 2 X Rod area
VP ext= VP ret

Drawback: Load carrying capacity during extension in a Regenerative

circuit is less than the regular double acting cylinder

APPLICATION OF
REGENERATIVE CIRCUIT
Drilling machine application

DRILLING MACHINE
The increase in extension speed is
compensated by reduction in load bearing
capacity of the regenerative circuits.
This is overcome by having a regenerated
connection in its central position of the
drilling circuit and the other positions (left,
right) act as a simple double acting
cylinder.

SYNCHRONISING CIRCUIT
Synchronization is the technique of
operating two cylinders to do identical
strokes
There are two ways to make the cylinders
operate in synchronization
i) Connecting the cylinders parallel
ii) Connecting the cylinders in series

Synchronization by connecting
cylinders in Parallel

Cylinders hooked in parallel will not operate in synchronization

F load

F load

Synchronization by connecting
cylinders in Parallel
The piping to two cylinders are parallel
The two cylinders cannot operate in
synchronization if connected in parallel because:

Loads on cylinders are not identical

No two cylinders are exactly identical

Synchronization by connecting
cylinders in Series
Cylinders hooked in series will operate in synchronization
CYLINDER 1

A-R1
F1

P1
A-P1

CYLINDER 2
F2

P2
A-P2

A-R2

Synchronization by connecting
cylinders in Series
This is the simplest, accurate and easiest way of
achieving synchronization.
The fluid from pump is connected to piston side of
cylinder 1 and fluid from rod side of cylinder 1 is
connected to piston side of cylinder 2 and fluid from rod
side of cylinder 2 is directed to tank via DCV.
For synchronization the piston area of cylinder 2 must be
equal to the difference between the areas of the piston
and rod for cylinder 1.

Synchronization by connecting
cylinders in Series

The pump flow should have the pressure rating equal to that
required for both the cylinders.

As per Pascals law,

P1AP1 P2(AP1-AR1)=F1
P2AP2 P3(AP2-AR2)=F2
Adding both these equations and also note
AP2=AP1-AR1 and P3=0;
P1AP1= F1+ F2

ACCUMULATOR CIRCUITS
Accumulators are devices that stores the potential
energy of the compressible fluid under pressure by an
external source against some dynamic force. The stored
energy is used to do useful work.
The Accumulators are used as

Auxiliary power source

As a leakage compensator
As a emergency power source
As a shock absorber

ACCUMULATOR AS AN
AUXILIARY POWER SOURCE
ACCUMULATOR

Accumulator as an auxiliary power source

ACCUMULATOR AS AN
AUXILIARY POWER SOURCE
The oil delivered by pump is stored by the
accumulator
The accumulator then delivers the stored oil on
demand
Useful to systems which has intermittent
operations
The oil flows form the pump as well as from the
accumulator to the cylinder and at the end of
strokes the oil from the pump is stored in the
accumulator.

ACCUMULATOR AS A LEAKAGE
COMPENSATOR

PRESSURE
SWITCH

Accumulator as a leakage compensator

ACCUMULATOR AS A LEAKAGE
COMPENSATOR
This is used for systems which operate for long period of
time.
The pump charges the accumulator to the maximum
pressure and when it reaches the pressure switch closes
the operation and pump. The further operation is
managed by the flow from the accumulator and when the
pressure reduces, the pressure switch once again starts
the pump and thus it prevents the functioning of pump
for a long period and also supplies the fluid as and when
required.

ACCUMULATOR AS AN
EMERGENCY POWER SOURCE

Accumulator as an
emergency power source

ACCUMULATOR AS AN
EMERGENCY POWER SOURCE
The accumulators are used to retract the
cylinders in case of power failures.
In the circuit, the fluid is passed to blank side,
rod side and through the check valve to the
accumulator. In any case the power fails, the
solenoid DCV is pushed to spring offset mode
and the accumulator supplies fluid towards the
retraction of the cylinder.

ACCUMULATOR AS A
HYDRAULIC SHOCK ABSORBER
TO SYSTEM

EMERGENCY
SHUT-OFF
VALVE

Accumulator as a hydraulic
shock absorber

ACCUMULATOR AS A
HYDRAULIC SHOCK ABSORBER
The hydraulic shocks are due to sudden
stoppage, deceleration of flow etc.. The shock
creates compression waves and travels at the
speed of sound and travels up and down until
their energy is lost as friction. This causes
damage to the components and if an
accumulator is placed near the rapidly closing
valve, the pressure pulsations are suppressed
and thus serves as a shock absorber.

SAFETY CIRCUITS
Fail Safe circuits are designed to prevent
injury to the operator or damage to
equipment.
In general it prevents the system from free
falling on the operator and prevent the
system from overloading.

FAIL SAFE CIRCUIT TO PROTECT FROM

CYLINDER FALLING
Fail-safe circuit

FAIL SAFE CIRCUIT TO PROTECT FROM

CYLINDER FALLING
In this circuit, the lowering of the cylinder will occur only
when the pilot pressure from the blank side of the
cylinder pushes the pilot operated check valve to allow
the flow from the rod side to pass through the DCV.
This is helpful in those places where inadvertent pushing
of the DCV takes place or rupture in the flow line occurs.

To insure safety the push button will be used to give the

pilot pressure to operate the DCV or only when manual
operation of the DCV is done the flow is passed to the
blank side.

FAIL SAFE CIRCUIT FOR OVERLOAD

PROTECTION
Fail-safe circuit with overload
protection
Valve 3

Valve 2

Valve 1

Valve 4

FAIL SAFE CIRCUIT FOR OVERLOAD

PROTECTION

Valve 1 is controlled by Valve 2.

Valve 3 drains Valve 2 in its spring offset mode

Valve 4 is operated when an increase in pressure due to overload is felt in the upward
line to the cylinder

When Valve 2 is operated, it pushes the Valve 1(DCV)

This transfers oil to the blank side and any increase in pressure operates Valve 4 and
this Valve 4 pilot operates Valve 3 and this drains Valve 1 and results in flow to the
rod side and prevents from further downward motion against load.

Any motion of Valve 2 now will not do anything and only at the retraction of Valve 4 or
manual pushing of Valve 3 only will result in downward motion of the cylinder.

TWO HANDED SAFETY SYSTEM

Two-hand safety circuit

TWO HANDED SAFETY SYSTEM

In this circuit the extension of cylinder will
occur only when both the push buttons are
pushed down
In this circuit the retraction will occur only
when both the push buttons are released
In any case, if one button is pressed there will
be no operation.

PUNCHING PRESS- DOUBLE PUMP CIRCUIT

Double pump hydraulic system

High pressure pump

Low pressure pump

PUNCHING PRESS- DOUBLE PUMP CIRCUIT

In this circuit there is a low pressure, high flow pump and high
pressure low flow pump, an unloading valve, a check valve, a
pressure relief valve and a double acting cylinder.

The high flow low pressure pump is used for rapid extension and
high pressure low flow pump delivers during the actual punching
operation.

The high flow pump during high pressure is protected by the check
valve and during punching, the flow is diverted through the
unloading valve back to the tank at low pressure.

This eliminates the need of a large high pressure, high flow pump.

An alternate circuit for punching is the pressure intensifier circuit.

PUNCHING PRESS-PRESSURE
INTENSIFIER CIRCUIT
Pressure intensifier circuit
F load
int

PUNCHING PRESS-PRESSURE
INTENSIFIER CIRCUIT
This circuit has a pilot operated check valve ,a pressure
intensifier placed close to the cylinder in the load
application direction and a sequence valve.
Once the flow is passed through the check valve, the
cylinder extends and when the pressure is required the
flow is passed to the intensifier through the sequence
valve that deliver the required pressure.
The return flow is through the pilot check valve
This eliminates the need of two pumps in a circuit.

SEQUENCING CIRCUIT
Hydraulic cylinder sequence circuit

SEQUENCING CIRCUIT
In this circuit if the DCV is shifted to the left, the left
cylinder extends completely and the right cylinder
extend.
If the DCV is shifted to its right, the right cylinder retracts
completely and then the left cylinder retract.
If Cylinder on left is clamping cylinder and Cylinder on
right is drilling, it can be taken for a clamp and drill
circuit.
This procedure can be adopted to all the machining
operations.