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HYDRAULIC SYSTEMS

1. Introduction

Hydraulic systems are used for transmission of power through the medium
of hydraulic oil. The hydraulic system works on the principle of Pascal’s law which
says that “the pressure in a fluid at rest is transmitted uniformly in all directions”
.

The fluid medium used is hydraulic oil, which may be mineral oil or water or
combinations. This area is also known as oil hydraulics.

The power transferred is:

Power = Pressure x flow rate in the tubes or hoses.

The schematic of a simple hydraulic system is shown in the figure below.

It consists of:

a movable piston connected to the output shaft in an enclosed cylinder

storage tank containing hydraulic fluid
filter which is in suction line of pump inside the tank or on tank inlet line.
Electric motor / diesel or petrol engine which is the primary source of power
Hydraulic pump driven by motor or engine
Pressure control valve
Leak proof closed loop piping.
Direction control valve which controls the direction of fluid flow so as to
change the direction of motion of a linear or rotary actuator
Actuator – A cylinder for linear movement or a hydraulic motor for rotary
actuation of load

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1.1 Applications of Hydraulic Systems

The chief advantage that hydraulic systems derive is from the high pressures
that can be applied leading to high force or toque by the actuating piston or
motor.

Pressures normally used in Industry are 140 bar (140 kgf/ cm2 ≈14 MPA ≈
2000 psi). But in some specific applications in machine tools and aerospace,
350 bar (35 MPa or 5000 psi) is also common.

Example: Consider an actuator with a 10 cms diameter piston. If the pressure

applied on the piston is 140 bar, Force that the piston rod delivers

F = Pressure x Area = 140 * π/4* 102 = 10,996 Kgf = 108 KN.

ie nearly 10 Tons of load can be applied using a 10 cms diameter cylinder.

If the pressure is 350 bar, load will be 25 Tons.

Similarly, high torques can be applied with a small sized motor compared to
an electric motor. The high Power / Weight ratio of the hydraulic actuators is the
prime reason for use of hydraulics.

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1.2 Application areas:

Hydraulic systems are generally used for precise control of larger

forces. The main applications of hydraulic system can be classified in five
categories:
Industrial: Plastic processing machineries, steel making and
primary metal extraction applications, automated production lines,
machine tool industries, paper industries, loaders, crushes, textile
machineries, R & D equipment and robotic systems etc.
Mobile hydraulics: Tractors, irrigation system, earthmoving equipment,
material handling equipment, commercial vehicles, tunnel boring
equipment, rail equipment, building and construction machineries and
drilling rigs etc.
Automobiles: brakes, shock absorbers, steering system, wind
shield, lift and cleaning etc.
Marine applications: Controls in ocean going vessels, fishing boats and
navel equipment.
Aerospace equipment: R udder control, landing gear, breaks, flight
control and transmission, rocket motor movement

1.3 Advantages and Disadvantages of Hydraulic systems

Advantages of Hydraulic systems

High power to weight ratio compared to electrical systems

Allows easy control of speed and position, and direction
Facilitates stepless power control
Allows combination with electric controls
Delivers c o n s i s t e n t p o w e r o u t p u t w h i c h i s d i f f i c u l pneumatic
t in or
mechanical drive systems
Performs well in hot environment conditions

Compared to Pneumatics:
Much stiffer (or rigid) due to incompressible fluid
Better speed of response
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Better lubricity (less friction) and rust resistance

Low maintenance cost.

Disadvantages

• Material of storage tank, piping, cylinder and piston can be

corroded with the hydraulic fluid. Therefore, one must be careful
while selecting materials and hydraulic fluid.
• Structural weight and size of the system is more which makes it
unsuitable for the smaller instruments.

• Small impurities in the hydraulic fluid can permanently damage the

complete system. Therefore, suitable filter must be installed.

• Leakage of hydraulic fluid is also a critical issue and

suitable prevention method and seals must be adopted.

• Hydraulic fluids, if not disposed properly, can be harmful to the

environment.

1.4 Relative advantages of different power transmission systems:

1.5 Hydraulic fluids:

The general requirements of fluids in power transmission are:

1. Low cost
2. Non-corrosive
3. Have infinite stiffness
4. Good lubrication properties
5. Store well without degradation
6. Non-toxic
7. Non-inflammable
8. Properties remain stable over wide range of temperatures.

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Many types of fluids are used ranging from water, mineral oils, vegetable
oils, synthetic and organic liquids. Water was the first liquid used and is very
cheap. But its disadvantages are – freezes easily, rusts metal parts, boils and
relatively poor lubricant. Mineral oils are far superior in these properties. Its
success also lies in – the ease with which their properties can be changed with
additives.

Additives used are - various chemicals like phenols and amines,

chlorine and lead compounds, esters, organo-metallic compounds,
for change in properties such as:
1. Antioxidants
2. Corrosion inhibitor
3. Rust inhibitor
4. Anti-foam
5. Lubrication improver
6. Pour point depressant
7. Viscosity index improver.

1.6 FILTERS

When hydraulic fluids are contaminated, hydraulic systems may get

damaged and malfunction due to clogging and internal wear. They require
filtration to remove contaminants.

Filters are classified as

i. Reservoir filters:
ii. Line filters
iii. Off-line filters
iv. Other cleaning equipment
1. Reservoir filters: These may be installed in the reservoir at the pump
suction port or in the return line cleaning the liquid returning to the
port.
Suction type filter consists of a core rolled up with a filter paper and
submerged in working fluid. Typically, they use 100-micron filter papers.
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Return filters or either mounted on the reservoir or in the lines.

Filtration ratings in return lines vary from 10 micron to 35-micron, lower
micron rating being used for higher pressures.
2. Line filters: These are installed when high filtration is required and are
used to avoid high suction at the reservoir filters. These are used with a
separate line connection. Filter selection depends upon pressure, flow
rate and filtration rating.
3. Off-line filters: These filters clean fluids in a reservoir using a dedicated
pump and filter separate from the line. These are used when higher
cleaning level is required.
4. Other equipment include air breather (filtering out dust in the air), oil
filling port or magnetic separator to absorb iron powders in reservoir.

1.7 ACCUMULATORS:

These are used to supply additional fluid when main line fluid pump is
inadequate to perform the actuation. Usually gas filled bladders at high pressure
act on the reservoir of fluid in the accumulator to make up for the required line
flow.
Accumulators are used:

i. to accommodate large flow rates or to compensate leakages.

ii. Absorb pulsations and reducing noise
iii. To absorb shocks.

Types:

i. Bladder type: Separates gas from oil by a rubber bladder

ii. Diaphragm type: Sometimes used as a small accumulator
iii. Piston type: Shaped as a cylinder without a rod
iv. Spring type, weight loaded type.

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2. P u mp

P u m p s u s e d i n hydraulic system a r e Positive displacement pumps.

(Rotodynamic pumps like centrifugal pump are not used)

Most commonly used pumps are

1. Gear Pump (External or Internal )
2. Vane Pump
3. Piston pump (Axial – Regular or Bent Axis type)
These pumps deliver a constant volume of fluid in a cycle. The discharge
quantity per revolution is fixed in these pumps and they produce fluid flow
proportional to their displacement and rotor speed. These pumps are used in
most of the industrial fluid power applications. The output fluid flow is constant
and is independent of the system pressure (load).
Points about pumps:
Positive displacement pumps
i. generates high pressure
ii. high volumetric efficiency
iii. high power to weight ratio
iv. have wide operating range pressure and speed

The fluid flow rate of these pumps ranges from 0.1 to 15,000 gpm, and
the pressure ranges between 1 to 700 bar.

Pressure is a back effect: Positive displacement pumps do not produce

pressure but they only produce fluid flow. The resistance to output fluid flow
generates the pressure. It means that if the discharge port (output) of a positive
displacement pump is opened to the atmosphere, then fluid flow will not
generate any output pressure above atmospheric pressure. But, if the discharge
port is partially blocked, then the pressure will rise due to the increase in fluid
flow resistance. If the discharge port of the pump is completely blocked, then an
infinite resistance will be generated. This will result in the breakage of the
weakest component in the circuit. Therefore, a safety valves called relief valve is
invariably provided in the hydraulic circuits.
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2.1 Gear Pumps

Gear pump is a robust and simple positive displacement pump. It has
two meshed gears revolving about their respective axes. These gears are the
only moving parts in the pump. They are compact, relatively inexpensive and
have few moving parts.
Gear pumps are most commonly used for the hydraulic fluid power
applications and are also widely used in chemical industries.

Based upon the design, the gear pumps are classified as:
• External gear pumps
• Lobe pumps
• Internal gear pumps
• Gerotor pumps

2.2 External gear pump

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2.3 Lobe Pump

Working: One of the two gears / lobes is connected to a motor and causes
rotation of the other. As they rotate in the direction shown, vacuum is created
on the inlet side, liquid is trapped between the gear teath / lobe and the motor
casing. On further rotation liquid is forced to the outlet side. The gear teeth or
lobes at the centre provide a seal between the inlet and outlet.

The volume displaced (dp) is product of the area entrapped and width
of tooth per each revolution and is constant. Flow rate is N x d p, where is the
speed of motor. (use appropriate units)

2.4 Internal Gear Pump:

Working : The internal gear is eccentric to the outer gear. Rotation of the
internal gear causes suction on inlet side, liquid is trapped between internal
gear teeth and the crescent seal, and is forced out to outlet port.

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Internal gear pumps are exceptionally versatile. They are often used for low or
medium viscosity fluids such as solvents and fuel oil and wide range of
temperature. This is non- pulsing, self-priming and can run dry for short periods.
It is a variation of the basic gear pump.

2.5 Vane Pumps

Gear pumps have a disadvantage of small leakage due to gap between gear teeth
and the pump housing. This limitation is overcome in vane pumps.

Working principle: The schematic of vane pump working principle is shown in

figure. Vane pumps generate a pumping action by tracking of vanes along the
casing wall.

The vane pumps generally consist of a rotor, vanes, ring and a port plate
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with inlet and outlet ports. The rotor in a vane pump is connected to the prime
mover through a shaft. The vanes are located on the slotted rotor. The rotor is
eccentrically placed inside a cam ring as shown in the figure. The rotor is sealed
into the cam by two side plates. When the prime mover rotates the rotor,
the vanes are thrown outward due to centrifugal force. The vanes track along
the ring. It provides a tight hydraulic seal to the fluid which is more at the higher
rotation speed due to higher centrifugal force. This produces a suction cavity in
the ring as the rotor rotates. It creates vacuum at the inlet and therefore,
the fluid is pushed into the pump through the inlet. The fluid is carried around to
the outlet by the vanes whose retraction causes the fluid to be expelled. The
capacity of the pump depends upon the eccentricity, expansion of vanes, width
of vanes and speed of the rotor. It can be noted that the fluid flow will not
occur when the eccentricity is zero.

2.6 Unbalanced Vane pump:

In practice, the vane pumps have more than one vane as shown in
figure

The rotor is offset within the housing, and the vanes are constrained by
a cam ring as they cross inlet and outlet ports. Although the vane tips are held
against the housing, still a small amount of leakage exists between rotor faces and
body sides. This type of pump is called as unbalanced vane pump.

2.7 Balanced vane pump

This pump has an elliptical cam ring with two inlet and two outlet ports.
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Pressure loading still occurs in the vanes but the two identical pump halves
create equal but opposite forces on the rotor. It leads to the zero-net force on the
shaft and bearings. Thus, life of pump and bearing increase significantly. Also,
the sound and vibration are less.

Balanced Vane Pump

2.8 Axial Piston Pump

Axial piston pumps are positive displacement pumps which converts rotary
motion of the input shaft into an axial reciprocating motion of the pistons. These
pumps have a number of pistons (usually an odd number) in a circular array
within a housing which is commonly referred to as a cylinder block, rotor or
barrel. In general, these systems have a maximum operating temperature of
about 120 °C. Therefore, the leakage between cylinder housing and body block
is used for cooling and lubrication of the rotating parts. This cylinder block
rotates by an integral shaft aligned with the pistons.

There are two types of axial pumps:

a. Bent axis piston pumps

b. Swash plate axial piston pump

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2.9.a Bent-Axis Piston Pump

In these pumps, the reciprocating action of the pistons is obtained by bending

the axis of the cylinder block. The cylinder block rotates at an angle which is
inclined to the drive shaft. The cylinder block is turned by the drive shaft
through a universal link. The cylinder block is set at an offset angle with the
drive shaft. The cylinder block contains a number of pistons along its periphery.
These piston rods are connected with the drive shaft flange by ball-and- socket
joints. These pistons are forced in and out of their bores as the distance
between the drive shaft flange and the cylinder block changes. A universal link
connects the block to the drive shaft, to provide alignment and a positive drive.

Bent Axis Piston pump

The volumetric displacement (discharge) of the pump is controlled by changing
the offset angle.

2.9.b Swash Plate Axial Piston Pump

A swash plate is a device that translates the rotary motion of a shaft into the
reciprocating motion. It consists of a disk attached to a shaft as shown in Figure
If the disk is aligned perpendicular to the shaft; the disk will turn along with the
rotating shaft without any reciprocating effect. Similarly, the edge of the inclined
shaft will appear to oscillate along the shaft's length. This apparent linear motion
increases with increase in the angle between disk and the shaft (offset angle).

The apparent linear motion can be converted into an actual reciprocating motion
by means of a follower that does not turn with the swash plate.

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Swash plate piston pump

In swash plate axial piston pump a series of pistons are aligned coaxially with
a shaft through a swash plate to pump a fluid. The axial reciprocating
motion of pistons is obtained by a swash plate that is either fixed or has
variable degree of angle. As the piston barrel assembly rotates, the piston
rotates around the shaft with the piston shoes in contact with the swash
plate. The piston shoes follow the angled surface of the swash plate and the
rotational motion of the shaft is converted into the reciprocating motion of
the pistons. Pump capacity can be controlled by varying the swash plate
angle with the help of a separate hydraulic cylinder.

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3 DIRECTIONAL CONTROL VALVES (DCV)

3.1 Directional control valves can be classified in a number of ways:

1. According to type of construction :

• Poppet valves

• Spool valves

2. According to number of working ports :

• Two- way valves

• Three – way valves

• Four- way valves.

3. According to number of Switching position:

• Two – position

• Three - position

4. According to Actuating mechanism:

• Manual actuation

• Mechanical actuation

• Solenoid (Electrical) actuation

• Hydraulic (Pilot) actuation

• Pneumatic actuation

• Indirect actuation

The designation of the directional control valve refers to the number of

working ports and the number of switching positions.
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3.2 How to read the valve schematic:

Symbols: P – Pressure port (high pressure oil inlet from pump) T
– Tank or return port connected to tank

A, B – Ports connected to actuator (eg., piston side and rod side of cylinder) The
figure below represents a 2 position, 4-way (or 4- port) valve.
The two rectangular blocks represent two positions of possible actuation of
valve. A, B, P and T are the 4 ports of the valve connected to different
components. Hence it is called a 2/4 valve.
The construction or design of the valve is such that when valve is actuated to left
side, as shown by arrows, pressure line from pump is connected to A side of
actuator, and B side is connected to the tank.

Similarly, when valve is switched to second position, the right side is effective.
(Now read the four symbols A, B, P, T on the four ports in right rectangle, which
is effective). From the arrows it means P is connected to B and A is connected to
T).

1. Check Valve: This valve allows flow from P to A., when pressure is enough to
overcome the spring force acting on the ball, which is quite small. It does not allow
flow in the other direction ie from A to P.

The symbol for check valve is as shown. It is also called On-off or Non-return
valve.
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The simplest type of directional control valve is a check valve which is a two-
way valve because it contains two ports. These valves are also called as on-off
valves because they allow the fluid flow in only in one direction and the valve is
normally closed. Two– way valves are usually the spool or poppet design with the
poppet

2. Spool type on/ off valve: As can be seen from the figure,

3. 2-position, 3-way valve

Symbol of 2/3 valve Position 0: A to T

Position 1: P to A
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4. Open center 3/4 DCV

18
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5. Closed Center 3 / 4 DCV:

6. Tandem centered 3 /4 DCV

7. Two position, Four – way DCV :

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3.3 Actuation of Directional control valves :

Directional control valves can be actuated by different methods.

Manually – actuated Valve: A manually actuated DCV uses muscle power to
actuate the spool. Manual actuators are hand lever, push button, pedals. The
following symbols show the DCV actuated manually

(a) (b)

Fig a & b shows the symbol of 2 / 4 DCV manually operated by hand lever to 1
and spring return to
2. In the above two symbols the DCV spool is returned by springs which push
the spool back to its initial position once the operating force has stopped.

Mechanical Actuation: The DCV spool can be actuated mechanically, by

roller and cam, roller and plunger. The spool end contains the roller and the
plunger or cam can be attached to the actuator (cylinder). When the cylinder
reaches a specific position the DCV is actuated. The roller tappet connected to
the spool is pushed in by a cam or plunger and presses on the spool to shift it
either to right or left reversing the direction of flow to the cylinder. A spring is
often used to bring the valve to its centre configuration when deactivated.

Solenoid Actuated DCV: A very common way to actuate a spool valve is by

using a solenoid is illustrated in the figure. When the electric coil (solenoid) is
energized, it creates a magnetic force that pulls the armature into the coil. This
caused the armature to push on the spool rod to move the spool of the valve.. The
advantage of a solenoid valve is that the switching time is less.
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Hydraulic actuation: This type actuation is usually known as pilot-actuated valve.

The hydraulic pressure may be directly used on the end face of the spool. The pilot
ports are located on the valve ends. Figure shows a DCV where the rate of shifting
the spool from one side to another can be controlled by a needle valve. Fluid
entering the pilot pressure port on the X end flows through the check valve and
operates against the piston. This forces the spool to move towards the opposite
position. Fluid in the Y end (right end, not shown in the figure) is passed through
the adjustable needle valve and exhausted back to tank. The amount of fluid bled
through the needle valve controls how fast the valve will shift.
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Indirect actuation of directional control valve

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4. Pressure Relief Valves

The pressure relief valve is used to protect the hydraulic components

from excessive pressure. It is one of the most important components of a
hydraulic system and is essentially required for safe operation of the system. Its
primary function is to limit the system pressure within a specified range. It is
normally a closed type and it opens when the pressure exceeds a specified
maximum value by diverting pump flow back to the tank. The simplest type
valve contains a poppet held in a seat against the spring force as shown in the
figure. The fluid enters from the opposite side of the poppet. When the system
pressure exceeds the preset value, the poppet lifts and the fluid is escaped
through the orifice to the storage tank directly. It reduces the system pressure
and as the pressure reduces to the set limit again the valve closes. This valve
does not provide a flat cut-off pressure limit with flow rate because the spring
must be deflected more when the flow rate is higher. Various types of
pressure control valves are discussed in the following sections:
1.Pressure Relief Valve: When the system pressure exceeds a set value,
the poppet raises up and allows fluid to flow rank.

2. Unloading Valve: A unloading valve is used to permit a pump to

operate at minimum load. The unloading valve is normally closed valve
with the spool closing the tank port. When a pilot pressure is enough to
overcome the spring force, spool moves up and flow is diverted to tank.
When the pilot pressure is relaxed, spool moves down and lets the flow
to the circuit for operation.
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The unloading valve is used in system having one or more fixed

delivery pump to control the amount of flow at any given time. A well
designed hydraulic circuit uses the correct amount of fluid for each
phase of a given cycle of machine operations. When pressure builds up
during the feed phase of the cycle, the pilot pressure opens the
unloading valve, causing the large discharge pump to bypass its flow
back to the tank.
3. Sequence valve: A sequence valve’s primary function is to divert
flow in a predetermined sequence. It is a pressure-actuated valve
similar in construction to a relief valve and normally a closed valve.
When the main system pressure overcomes the spring setting, the
valve spool moves up allowing flow from the secondary port.
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4. Counter balance Valve: A counter b a l a n c e v a l v e i s u s e d t o

m a i n t a i n b a c k pressure to prevent a load from failing. One can find
application in vertical presses, lift trucks, loaders and other machine
tool that must position or hold suspended loads.

When a counterbalance valve is used on large vertical presses, it may

important to analyze the source of pilot pressure. Figures (a) and (b)
illustrate the comparison between direct and remote pilot signal

(a) (b)
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5. Pressure Reducing Valve: Pressure reducing valve is used to limit its

outlet pressure. Reducing valves are used for the operation of branch
circuits, where pressure may be less than the main system pressure.
The pressure reducing valve is normally an open type valve. When
the secondary pressure is high, it lifts the spool against the spring force
and throttles the flow till such extent that the secondary pressure
reaches the value as set by spring.
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5. SOME TYPICAL HYDRAULIC CIRCUITS

5.1 In this part we will look at some of the simple and commonly encountered
hydraulic circuits. The circuits are drawn using the standard graphical symbols.

5.1.1 Control of a Single- Acting Hydraulic Cylinder

In single acting cylinder hydraulic force is exerted on the piston for forward
movement (to right in the figure shown). For retraction, no hydraulic force is
applied and the rod moves (to left) due to a spring force or weight of the piston
and rod
Figure shows a two-position, three way, manually operated, spring offset
directional control valve (DCV) used to control the operation of a single – acting
cylinder.

As valve is moved to occupy position 1 (left) flow goes to rod end and rod is pushed
to right.

When valve is moved to position 0, i.e. shifted to right indicated position,

flow from pump is blocked in the valve. There is no hydraulic pressure on the
piston side. The flow goes to tank via relief valve at the set pressure. The
actuator moves to left due to spring force acting on the rod end of piston.
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5.1.2 Control of Double Acting Hydraulic Cylinder:

Double –Acting cylinders can be extended and retracted hydraulically. Thus, an
output force can be applied in two directions.

Double acting cylinder

The valve is manual 3postion /4-way valve. In the neutral or valve central (0)
position, oil from pump goes to tank, and no action on actuator. Note that the
valve does not go through relief valve to tank, thereby saving power (Pressure set
in relief valve x pump flow rate). There is minor power loss due to drop in valve
orifices, and piping.

In position 1 of valve, oil flow is P to A. ie. from pump to piston side and rod
moves to right acting on the load. Oil from rod side chamber of cylinder goes
to tank (B to T).
In position 2, Oil from pump goes to rod end (P to B) and Oil from piston end
goes to tank. (A to T) thereby pushing the rod (load) to left.

5.1.3 Regenerative circuit:

Operation: Figure shows a regenerative circuit that is used to speed up the

extending speed of a double-acting hydraulic cylinder.
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It can be seen that in position 1 when pump is connected to piston side

chamber ,ie., when main load is operated, fluid from piston side also flows into it.
Thereby the flow rate is more than pump flow. Thus the velocity of actuation on
piston side is increased by the ratio ( Ap / Ar), where Ap is the piston area and Ar
is the rod area. . However, the net force due to the piston rod is reduced to Ar x
Pressure. In position 2, when flow is directed to rod side, oil from the piston side
flows to tank directly.
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5.1.4 Pump Unloading Circuit

The figure shows a circuit using an
unloading valve to unload a pump. The
unloading valve opens when the cylinder
reaches the end of its extension stroke because
the check valve keeps high-pressure oil in the
pilot line of the unloading valve. When the DCV
is shifted to retract the cylinder, the motion of
the piston reduces the pressure in the pilot line of
the unloading valve. This resets the unloading
valve until the cylinder is fully retracted, at which
point the unloading valve unloads the pump.
Thus, the unloading valve unloads the pump at
the ends of the extending and retraction strokes
as well as in the spring-centered position of the
DCV.

5.1.5 Counter Balance Valve Application

Counter balance valve is used to hold
loads in vertical position without descending
while idling in neutral position. Rod side fluid
cannot flow unless a pilot pressure acts on the
valve and permits flow to tank. The valve
spring so set that pressure required is higher
than for upward stroke.
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5.2 Hydraulic Cylinder Sequencing Circuits:

Figure shows an example where two sequence valves are used to control the
sequence of operations of two double-acting cylinders C1 and C2. When the DCV
is shifted into its left position, the left cylinder extends completely, and pressure
builds up and only when the left cylinder pressure reaches the pressure setting of
sequence valve, the sequence valve connected to the right cylinder opens and
permits flow to rod end of C2, and extends it.
If the DCV is then shifted to right position, flow to rod end of C1 is blocked, but
flows freely to rod end of C2. After C2 retracts fully, pressure builds up till the
valve connected to C1 opens.
Thus the sequence is C1Ext - C2Ext - C2Retr – C1 Retr.
One can find the application of this circuit in press circuit. For example, the left
cylinder the clamping cylinder C1 could extend and clamp a workpiece. Then the
right cylinder C2, the punching cylinder extends to punch a hole in the workpiece.
The right cylinder then retracts the punch, and then the left cylinder retracts to
declamp the workpiece for removal.
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5.3 Automatic Cylinder Reciprocating System –

(i) Using Sequence Valves
Operation: In the left position of valve shown,
P is connected to rod-side, and the rod
retracts. After piston reaches the left end,
pressure builds up on rod side which opens
the sequence valve on the right and permits
pilot hydraulic line to act on the main DCV to
switch to right position. Check valves allow
pilot oil to leave either end of the DCV while
pilot pressure is applied to the opposite end.

(ii) An alternative circuit is shown using limit switches and solenoid valve,
and a pilot operated DCV.
Operation: Suppose the left
position of the main DCV is on.

Then the piston rod moves to

right > It hits the limit switch 2 >
which energises solenoid valve D2
> which shifts the solenoid
operated DCV (D2) to position
(top as shown) > which now
permits pilot oil from D2 to right
end of DCV D1 > changes D1
position 2 > flow is now to rod
end > rod moves to left till it hits
limit switch 1.
Now the reverse of the above
sequence is repeated so that
Position 1 of the main DCV
becomes operative. Thus, it leads
to automatic reciprocation of the
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actuator between the limit switch

positions.

5.4 Cylinder Synchronizing Circuits:

Circuits are shown for synchronising the operation of two cylinders (ie
simultaneous equal movement).

a. Cylinder connected in Parallel

In the circuit shown, piston or rod ends of both cylinders are connected to one
line. Thus oil flows simultaneously. However, if load on one cylinder is more,
the other cylinder needing less pressure operates first, and after completion of
stroke, pressure builds up to operate the second cylinder. This operation is not
synchronised. The problem may arise with slight differences in the size of
cylinders as well.
b. Cylinders connected in Series: The rod end of C1 is connected to piston end of
C2.
Thus C1 and C2 have to move together. However, for to have equal stroke, rod
end area of C1 should be equal to piston area of C1. Also, rod end of C2 has to
have high pressure to do work by C2. Hence piston side pressure would be that
much higher.
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5.5 Speed Control

Speed control of Hydraulic Cylinder: Speed control of a hydraulic cylinder is

accomplished using a flow control valve. A flow control valve regulates the
speed of the cylinder by controlling the flow rate to and of the actuator.

There are 3 types of speed control:

• Meter-in circuit (Primary control)
• Meter-out circuit (Secondary control)
• Bleed -off circuit (By pass control)

1. Meter-in Circuit : In this type of speed control, the flow control valve is
placed between the pump and the actuator. Thereby, it controls the
amount of fluid going into the actuator. Figure below shows meter-in
circuit. When the direction is reversed, oil from piston side flows to
tank via check valve as well as FC valve freely. The excess flow is
dumped to tank via relief valve.

2. Meter – out Circuit: In this type of speed control, the flow control
valve is placed between the actuator and the tank. Thereby, it controls
the amount of fluid going out of the actuator and thereby the speed of
retraction.
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Meter out circuits are useful to control free fall of loads due to gravity etc.
connected to the load. Oil is dumped at load pressure but not at relief
valve set pressure.
However, meter –out can lead to high pressure intensification sometimes
twice supply pressure, leading to damage of seals etc. Still it is
favoured in drilling, reaming and milling when it is required to control the
tool feed rate.

3. Bleed off circuit: This circuit is used to

overcome the disadvantages of meter-
in and meter- out circuits. Here, a flow
control valve is kept between either
ends. Flow is controlled in each
direction, and excess flow to tank is not
through relief valve.
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