UNIT - III

DESIGN OF HYDRAULIC
CIRCUITS
 SYLLABUS

Accumulators, Intensifiers, Industrial hydraulic circuits –

Regenerative, Pump Unloading, Double- Pump, Pressure
Intensifier, Air-over oil, Sequence, Reciprocation,
Synchronization, Fail-Safe, Speed Control, Hydrostatic
transmission, Electro hydraulic circuits

Mechanical hydraulic servo systems.

ACCUMULATORS AND
INTENSIFIERS
 ACCUMULATORS
• An Accumulators is basically a pressure storage reservoir in which a
non- compressible hydraulic fluid is retained under pressure from an
external source
• Definition :
• A hydraulic accumulator is a device that stores the potential energy of an
incompressible fluid held under pressure by an external source

• Suitability
• For hydraulic shock suppression
• For fluid make up in a closed hydraulic system
• For leakage compensation
• For emergency power in case of power failure
• For holding high pressure for longer period of time with out keeping the pump unit
in operation

• Application
• Large hydraulic presses
• Hydraulic lifts
• Cranes
• Power brakes
• Landing gear mechanism in air planes etc.
 ACCUMULATORS

• Types
• Weight loaded or dead weight loaded
• Spring loaded
• Gas loaded
Weight loaded accumulator
Spring loaded
Gas loaded • Non seperator Type
accumulator

Types :
1. Non – Seperator Type
2. Seperator type
1. Piston Type
2. Diaphragm Type
3. Bladder Type
 Seperator type
• Piston type
Diaphragm type
Bladder Type
ACCUMULATOR SYMBOLS
 Accumulator circuits
• Leakage compensator
• Auxillary Power Source
• Emergency Power Source
• Hydraulic Shock absorber
Accumulator as a Leakage Compensator circuit
Accumulator as Auxiliary Power Source circuit
Accumulator as Emergency power Source Circuit
Accumulator as Hydraulic shock absorber Circuit
INTENSIFIER
 PRESSURE INTENSIFIER
• It is also called as Pressure Boosters
• It is used to compress the liquid in a hydraulic system to a
value above the pump discharge Pressure.
• It is placed in between pump and the machine
• Its action is equal to the step up electrical transformer
Pressure Intensifier
Intensifier Symbols
 INDUSTRIAL HYDRAULIC CIRCUITS
1. Regenerative Circuit
2. Pump Unloading Circuit
3. Double- Pump Circuit
4. Pressure Intensifier Circuit
5. Air-over oil Circuit
6. Sequence Circuit
7. Reciprocation Circuit
8. Synchronization Circuit
9. Fail-Safe Circuit
10. Speed Control Circuit
11. Hydrostatic transmission
12. Electro hydraulic circuits
Control of single acting hydraulic cylinder
Control of double acting hydraulic cylinder
Regenerative circuit
PUMP UNLOADING CIRCUIT
PUMP UNLOADING CIRCUIT
Double- Pump Circuit
Double- Pump Circuit
Pressure Intensifier Circuit
Air – Over Oil Intensifier Circuit
Hydraulic cylinder sequencing circuit (clamping &
punching)
Automatic cylinder reciprocating system
Synchronizing hydraulic cylinder by connecting them in
series
Hydraulic circuit for drilling machine
Meter -in speed control of hydraulic cylinder using flow
control
Meter – out speed control of hydraulic cylinder using
flow control
Speed control of hydraulic motor using flow
control valve
Two handed safety control circuit
 Hydrostatic Transmission

The hydrostatic transmission allows the Vehicle to convert

mechanical energy into hydraulic power and then back to
mechanical energy.
What is Transmission?
Transmission of power using interconnected
devices from one point to another is called power
transmission.
Types:
1. Mechanical
2. Electrical
3. Hydrodynamic
4. Hydro mechanical
5. Hydrostatic transmission
are some categories of power transmission
Hydrodynamic Transmission:
• In hydrodynamic transmission, a hydrodynamic pump and
hydrodynamic motor are connected together. The power
generation is the result of the change in fluid velocity as it passes
through the channel. An automatic car is one of the applications
Hydrostatic Transmission:
• Simply, it is a hydraulic system where the hydraulic pump or an
accumulator will drive the motor using the fluid passing through
flexible hoses. In hydrostatic transmission, gears are not required
for converting rotating mechanical energy from one source to
another. Because, when the displacement of pump and motor are
fixed, then hydrostatic transmission itself will act as a gearbox.
Hydrostatic transmission is suitable for applications that require
variable output velocity or torque. Some of these applications
include golf-course maintenance equipment, harvesters, tractors,
trenchers, agricultural and large construction equipment.
The advantages of the hydrostatic transmission system
• With a constant input speed, hydrostatic transmission can
deliver variable output speed and vice versa.
• In a minimum time period, reverse direction of output rotation
is possible.
• Adjustment of speed, power and torque is possible with
hydrostatic transmission.
• Smooth and controlled acceleration.
• Fast response.
• Precise speed under variable load.
• Hydrostatic transmission can be stalled without damage or
overheating.
• Ease of control.
• Provide dynamic braking.
• Hydrostatic transmission can transfer power from one prime
mover to different locations.
• Compact size
Working Principle
The transmission allows an engine’s power to be multiplied
and manipulated to drive your vehicle forward and
backward. The hydrostatic transmission allows the Vehicle
to convert mechanical energy into hydraulic power and then
back to mechanical energy. This allows us to infinitely
change the variation of forward and reverse speed, and
makes our transmission unit smaller without sacrificing
power.
• The speed of your transmission’s output is dependent on
the rate of volume the oil is flowing. This is measured in
gallons per minute (GPM)
• The direction of your transmission’s output is dependent
on which direction the oil is being pumped.
• The power of your transmission’s output is dependent on
the oil’s pressure.
So the faster the oil is pumped from one side of the
transmission to the other, the faster your tractor moves, and
the higher the pressure, the stronger it turns.
 Components
1. Transmission Case
2. Charge Pump
3. Input Shaft
4. Axial Piston Pump
5. Oil Passageways
6. Pressure Relief Valves
7. Axial Piston Motor
8. Swash Plate
9. Check Valves
 Components
Transmission Case
• The case holds all of components in place and has
passageways to move oil from the pump to motor and back
again in a closed circuit.
Charge Pump
• The charge pump provides initial case oil pressure and fills
the case and circuits with oil. The charge pump also
provides oil flow for auxiliary hydraulic ports.
Input Shaft
• The input shaft takes power from the engine and rotates the
charge pump and the axial piston pump in the
transmission.
 Components
Axial Piston Pump
• This pump is the heart of your hydrostatic transmission. It is rotated by
the input shaft and contains the pistons that pump oil to the hydraulic
motor on the other end of the transmission.
Oil Passageways
• The passageways are hollow sections in the case that connect the
Piston Pump to the Piston Motor.
Pressure Relief Valves
• The pressure relief valves offer an alternative path for oil to flow when
the oil pressure reaches a predetermined amount. The pressure relief
valve contains a spring that holds a poppet in place to prevent oil from
flowing through it. When the oil pressure is able to overcome the spring
pressure, the valve opens up allowing oil to pass through it. The
Sundstrand Transmission has a charge relief valve, and in some cases
has an implement relief valve built into it.
 Components
Axial Piston Motor
• This motor is what drives the output shaft as a result of oil flowing
through it.
Swash Plate
• The swash plate changes the displacement of the piston pump. It does
this by changing angle in relation to the pistons. This allows the pistons
in the pump to pump more oil, less oil, and change direction. The
greater the angle of the swash plate, the longer the pistons stroke which
pumps a higher volume of oil to the motor. The higher the volume the
faster the motor goes. When the swash plate is perfectly parallel to the
pistons, there is no pumping action. The entire cylinder block just
rotates with the input shaft. With no pumping action, the transmission
is in neutral. When the swash plate is tilted in the other direction, the
pistons rotate backwards pumping oil in reverse, causing the motor to
rotate in the opposite direction.
Check Valves
• Check valves keeps oil in the closed circuit loop between the pump and
motor. They can be disengaged either automatically or manually to
allow oil pressure to escape so the tractor can be pushed.
Hydrostatic Transmission diagram
 Working
• The oil begins in the reservoir which is the rear differential case
on the vehicle. As the engine runs it rotates the drive shaft.
• The drive shaft is connected to the input shaft which turns both
the charge pump and the axial piston pump. The charge pump
draws oil up through the oil filter, and into the transmission case.
• Oil flows into the case, and into the closed circuit oil
passageways.
• As the operator moves the transmission control lever, the swash
plate changes angle and causes the pistons to move in and out of
the piston cylinder as it rotates.
• The reciprocating motion of the pistons causes oil to circulate
through the oil passageways and into the axial piston motor.
• Since the motor is set against a fixed angle, the pistons cause the
motor to rotate as it pushes oil back to the pump.
• The motor is connected to the output shaft that turns a large bull
gear in the differential and power is transferred to the rear
wheels.
Electrical Controls for Fluid power
System
 Electrical Controls for Fluid power System
• Manual operations are shifted to electrical control in fluid power
systems for the following reasons
– For easy controlling
– Provide quick and accurate operations
– Require less maintenance
– Better reliability
– Longer service life

Types of Electrical Control Devices

1. Push – Button Switches
2. Limit Switches
3. Pressure Switches
4. Temperature Switches
5. Solenoids
6. Relays
7. Timers
 Push – Button Switches
• They are primarily used for starting and stopping of
machinery.
• It also provide manual operation when emergency arises.
• These switches are called “Momentary Switches” as they
Make or Break Contact only as long as they are held under
pressure.
• the four commonly used types are
• Single Pole – Single Throw – Normally Open type (SPST – NO)
• Single Pole – Single Throw – Normally Close type (SPST – NC)
• Double pole – Single Throw type (DPST)
• Double pole – Double Throw type (DPDT)
Types of Push - Buttons
 Limit switches
• It is used to identify the extreme limit of the cylinder
actuation
• Difference between Push Button & Limit Switch
• Push Buttons are actuated Manually where as Limit Switches Are Actuated
Mechanically Actuated Devices
 Pressure Switches
• It is used to sense a change in pressure Automatically and
opens and closed an electrical switch when a pre- determined
pressure is reached
• Example
• Pump ON /OFF high pressure – OFF / Low Pressure – ON
 Temperature Switches
• It is used to sense a change in Temperature Automatically and
opens and closed an electrical switch when a pre- determined
Temperature is reached
 Solenoids
• It is electromagnetic mechanical Transducer
That Converts an electrical Signal in to
Mechanical output Force
 Relays
• It offer simple ON/OFF Switching action or it simply called as
electrical operated switches.
• Relays are commonly used to open or close the contacts and
there by energize or de energize the solenoids which operate
at a high current level
 Timers
• It is also called time delay relays
• It is used to control the duration of working cycle
• Timers are commonly applied in electrical control circuits
when a time delay from the instant of actuation to the closing
of contacts is required
• The timer can be adjusted to change the dwell period for
many machining operations
 Ladder diagram
• It is an electrical diagram showing the hardware connections
between the various electrical control devices
• Legs & Rungs
• The two vertical electrical power supply lines are called Legs and the
Horizontal lines Containing electrical components are called Rungs
• In ladder diaqgram always the power is connected to the left leg and the
ground is connected to the right leg
Electro Hydraulic Circuits
 Control of a cylinder using a single limit switch

- When Push button pressed - relay coil 1CR energize – closes both set of
1CR
The upper 1CR used to energize the coil 1CR even though the push button is
released
- lower 1CR used to energize Sol A, as Sol A energize cylinder extends
- at end of extension the piston rod cam actuates 1LS(NC) it opens
- it de-energize the Sol - A
- this make the valve to bring to spring off set mode and the cylinder retracts
 Reciprocating of a cylinder using Pressure
Switches

When Sol-A is energize , the 4/2 DCV is in left side it extends the cylinder
After extension pressure builds up and actuate the 1PS
- 1PS energize Sol- B at this time 4/2 DCV is in right side, so the cylinder
retracts
- again the pressure builds up in the rod side it actuates PS-2
- PS-2 energize the Sol- A thus the operation is repeated
 Reciprocating of cylinder using limit switches

When 1-LS is actuated it energize the Sol-A and cylinder extends

The extension of the cylinder rod actuates the 2-LS and 1 – LS was
released
- this de-energize the Sol- A and Sol- B energizes , so the 4/2 DCV is
shifted to right side thus the cylinder retracts and when it reaches the 1-LS
it actuates it
- thus the operation was repeated and the cylinder was reciprocated
continiously
 Dual – cylinder Sequencing circuit

Start button is pushed – energizes Sol-A – the 4/2 DCV V1 is positioned to left
side and the cylinder1 extends. The extension of Cyl 1 actuates the 1-LS.
1-LS energizes the Sol- C so the 4/2 DCV V2 is shifted to left position and thus
the Cylinder 2 extends. This extension of cylinder actuates 2-LS
- The 2-LS energizes the Sol- B and the DCV V1 is shifted to right side and the
cylinder retracts and 1-LS is released so that Sol- C De- energizes and the DCV
V2 is shifted to right side by the spring tension and now the cylinder 2 retracts
Regenerative Circuit
•1 SW is manually shifted to extend
•Sol-A energize and 4/3 DCV is shifted to
left side
•The oil pressure extends the cylinder
•The oil from the rod end is not passed to
drain it is connected with the inlet oil
pressure . This facilitate the rapid extension
of cylinder and the pressure starts to build
up in side the cylinder
•The build up pressure actuates the 1-PS
this energize the coil 1-CR and also Sol-C
•Now the 2/2 DCV V2 is shifted to left side
and it direct the oil from the rod end into oil
tank
•When 1 – SW is manually operated to
retract position the Sol- B is energized.
•This shift the 4/3 DCV V1 to right side and
it forces the oil in to the rod end of the
cylinder thus the cyllinder fully retracts
•When the 1-SW is manually shifted to
UNLOAD position all the solenoids are
de- energize and the 4/3 DCV V1 will
be in the center neutral position to
unload the pump.
Mechanical hydraulic servo
systems.
 SERVO SYSTEMS
• A servo control system is one in which a
comparatively large amount of power is controlled
by small impulses or command signals and any
errors are corrected by feed back signals
 A block diagram of a basic closed loop servo circuit

1. Command signal – it is derived from the punch card , tape , tachometer etc
2. Servo amplifier – receives low power input and amplify to high power level
3. Servo valve – receives the O/P signal from amplifier to actuate the torque motor
4. Actuator - it could be linear or rotary accordingly it actuates
5. Load
6. Feed back transducer – it may LVDT , tachometer , potentiometer etc

The difference between the output signal and the command signal is called the
“error” the purpose of the servo system is to bring the error signal to zero
THE END