Hydraulic Symbols Tutorial

This is a good tutorial for people who would like to know more about hydraulics but have not been able to find a good resource. If you would like to know an excellent resource for information on hydraulics then purchase the Fluid Power Designer Lightning eference !andbook by Paul "unroe !ydraulics# it is highly recommended.

Fluid Power Symbols

Hydraulic Tank (fluid reservoir) $ll hydraulic systems must have some form of a reservoir to hold the fluid in the system. "ost systems have vented tanks# however aircraft are one application where a closed tank is appropriate. The symbol shown here is a vented tank# a box with the line in the center would indicate a closed system. The line could also not go to the bottom of the tank# that would mean that the line stops above the fluid level in the tank and the fluid falls in. It is better to stop the line below the fluid level# otherwise the falling fluid may cause bubbles in the fluid.

Hydraulic Pump $ pump displaces fluid which creates flow. There are fixed displacement pumps and variable displacement pumps. The pump symbol is very similar to a hydraulic motor symbol# the difference is that the pump has the small triangle pointing out and a motor has the small triangle pointing in to the center. $n angled arrow typically indicates that a device is variable# thus this is a variable volume pump. Fixed displacement pumps provide the same output volume with the same input P". %ariable displacement pumps can change the output volume while maintaining the same input P". !ydraulic pumps are precision components and have very close tolerances# they must be treated with care.

Hydraulic Line !ydraulic lines carry the fluid from the pump throughout the system. There are two basic types# rigid and flexible. igid lines are used to connect items that will not move in relation to each other. "anifolds connected with rigid lines are the most reliable transfer method. The dots at the end of the line show a connection point# if two lines cross and this dot isn&t shown then the lines are not connected.

Hydraulic Hose (flexible line) $ flexible line is used to carry fluid to items that have a lot of vibration or movement in relation to each other. 'ome examples where flexible lines are used# the pump unit (vibration) or blades on a tractor# due to the movement.

Pressure Relief Valve

!ydraulic fluid is virtually non compressible# if the fluid can&t go anywhere the pump will stall# and damage to the pump and motor can result. $ll hydraulic systems must have a pressure relief valve in line with the pump. The pressure relief will drain into the tank. The dashed line indicates a pilot line# this is a small line that only flows enough fluid to control other valves. The pressure of this pilot line acts against the spring on the other side of this valve. *hen the pilot pressure exceeds the spring force then the valve spool shifts over and opens the valve# this allows flow to the tank. This causes a drop in the pressure on the pump side# which also reduces the pilot pressure. *hen the pilot pressure is less than the spring force the spring closes the valve. The relief valve in the position described above will control the maximum pressure in the hydraulic system. Directional Valves $ directional valve will control which device the fluid will flow to. These valves are the primary devices used to se+uence the motion of e+uipment. There are many different types of directional control valves. The valve is generally specified by number of positions and number of ays (ports)! The valve is made up of two parts# the body and the spool. *hen valves shift the spool is moved in relation to the body# this opens and closes passages that the fluid flows through. emember that the valve actuator always pushes the spool# this will help you read the drawings. ,ou read the operation of a valve in a circuit in the following manner. The box(s) with arrows in it show the flow of fluid when the valve is shifted. The box without arrows and-or away from the actuator shows the flow# if any# in the neutral position. This is also the box you use to count the number of ports the valve has.

T o(") Position# T o(")

ay

This valve has two positions (. boxes) and . ways (ports)/ thus . position# . way. It is shown with a manual actuator (on the right) and has a spring return to neutral. This valve is called normally closed because both ports are blocked when in neutral. It could be used on a safety device like a safety gate# if the gate isn&t closed# actuating the valve# then the flow will be stopped# preventing movement of the connected device.

T$ree(%) Position# &our(')

ay

This valve has three positions (0 boxes) and 1 ways (ports)/ thus 0 position# 1 way. It is shown with a closed center# when the valve is neutral all ports are blocked. The small boxes on each end with diagonal lines through them# 23 and 2.# are electrical coils# this is an electrically actuated valve. The port marked P is Pressure and the port marked T drains to tank. The ports marked $ and 4 connect to an external device# like a cylinder. *hen 23 is energi5ed the valve will shift# putting pressure to the 4 port and draining the $ port to the tank. Likewise when 2. is energi5ed the pressure port connects to the $ port and the 4 port drains to the tank.

T$ree(%) Position# &our(') (ay This valve has three positions (0 boxes) and 1 ways (ports)/ thus 0 position# 1 way. It also is electrically actuated. The 6agged lines next to the coil indicates springs# when the coil is de7energi5ed the opposite spring will force the spool back to the center position. This valve also drains to tank when in neutral# this is a standard valve on molding machines. They drain to tank when de7energi5ed for safety.

)ylinder

$ cylinder is one of the devices that creates movement. *hen pressure is applied to a port it causes that side of the cylinder to fill with fluid. If the fluid pressure and area of the cylinder are greater than the load that is attached then the load will move. 2ylinders are generally specified by bore and stroke# they can also have options like cushions installed. 2ushions slow down the cylinder at the end of the stroke to prevent slamming. If the pressure remains constant a larger diameter cylinder will provide more force because it has more surface area for the pressure to act on.

* )omplete )ircuit

Some +asic Hydraulic &ormulas If you use formulas occasionally a handy trick is to set up a spreadsheet that has the formulas built in# then all you need to do is enter the numbers. Pump ,utlet &lo The outlet flow of a pump in 8P" is9 Flow (8P") : P" ; Pump Displacement(2u.in.- ev) <<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<< .03 *rea of a )ylinder 4oth the force and speed of a cylinder are dependent on knowing the area of the cylinder. Remember t$at t$e area on t$e rod end of a cylinder is different t$an t$at of t$e non rod end! ,ou must subtract the area of the rod itself from the overall area of the cylinder. The same formula can be used to determine the area of the rod. $s you will see when pressure is applied to the rod end of the cylinder (pump pressure and volume constant)# it will move faster and have less force! $rea ('+.In.) : Pi ; Diameter=. <<<<<<<<<<<<<<<<< 1 $rea (rod end) : $rea 7 area of the rod itself

&orce of a cylinder $ cylinder usually has two forces# the force when applying pressure to side with the rod# and the side without the rod. $n exception can be a double ended cylinder# it has a rod end sticking out of each cylinder end. This can also be applied to pneumatics. Force : Pressure (P'I) ; >et $rea ('+. In.)

Speed of a cylinder

>ote 7 Inaccuracies have been discovered in the following e+uation and are being evaluated.
The speed of a cylinder is dependent on the flow rate to the cylinder and the area of the cylinder. This formula assumes no loss of fluid over a relief valve. %elocity (Ft.-'ec.) : .03 ; Flow ate (8P") <<<<<<<<<<<<<<<<<<<<<<<<<<< 3. ; ?@ ; >et $rea ('+.In.)

H-DR*.L/) 3 P01.2*T/) ),0TR,L

&L./D P,(1R 4R*PH/) S-2+,LS The standard icons to graphically represent fluid power components are defined in the $ustralian standard A Graphic symbols for general engineering - Hydraulic and pneumatic systems. The following are some of the components9

The valve designation is as follows9 p5n D2% : Directional 2ontrol %alve with n settings and p ports. It can be >ormally Apen (>A) or >ormal The port numbers on D2%s have the following standard designation9

Port >umber 3 0 .# 1

Designation Pressure port (coming from the pump) Bxhaust port (back to the tank) Autput ports

V*R/*+L1 &L,( V*LV1S The great of ma6ority of the valves used in fluid power applications are discrete valves as represented by the ab The opening area for these valves are constant and can be either open or closed. In variable flow valves# the flow area is a function of the spool position. 4y ad6usting the spool position# one c rate.

The flow rate obviously depends on the flow area as well as the pressure difference across the valve. Anly the controlled by the spool position. Therefore# if precise control of the flow rate is essential# then a control loop has that modulates the spool position to keep the flow rate constant. 'uch valves are called the servov Valve selection The choice of the valve is an important consideration in any fluid control application. This choice is a usually co the control re+uirements and the system cost. In difficult environments (eg mining or construction industry)# r factor. 4est control performance is usually offered by servo valves due to their good linearity and high bandwidth !owever# these valves have a very low tolerance against contaminants in the hydraulic oil. The standard of clea a servovalve may be difficult to achieve and maintain in CdirtyC environments. In some instances# capacity may For large machines# it simply is not possible to find a servovalve with the re+uired flow capacit egular directional control valves can be made extremely robust and are available at the desired si5e and they option for 6obs where control re+uirements are not too demanding. 'olenoid7driven proportional directional valves ('DPD%) provide a reasonable trade7off. 'DPD%s are relativel control world. They were introduced in the 3DE@s and they have become very popular since then due to their effectiveness. Their severe non7linearity (in comparison with the servovalves)# however# may offer a significan control designer. 16*2PL1S ,& &L./D P,(1R ),0TR,L *e will now provide some examples of how the fluid power components are connected and controlled to perf The examples all use simple D2%s. The treatment of proportional or servo7valves are beyond the scope o )ontrol of a sin7le8actuatin7 ram E ample! Draw the hydraulic circuit and the electrical diagram for a hydraulic ram. The piston is to be extende switch is closed. The piston should return back when the switch is released. Fse a single7acting cylinder a Ans"er !

E ample! $ hydraulic press is controlled by two manual switches placed 3 m apart (switches '3 and '.) and representing the status of the protective cover. The switch '0 is automatically closed when the protective c The press is to be activated whenever (a) both '3 and '. are A>/ or (b) either of the '3 or '. and '0 are A>.

Ance the press is activated# it will stay down until a normally closed lift button switch ('1) is released and br Design a hydraulic circuit and the electrical logic to drive this hydraulic press. Ans"er! There is a deliberate mistake in the PL2 diagram. 'ee if you can spot it.

>otes9 3. The symbol '3 appears twice on the PL2 diagram. It refers to signals from the same switch on the hyd .. ditto for '.. 0. G is the relay that engages the latch switch. The latch switch provides the signal for the solenoid relay H eve are broken. 1. '1 is the 'TAP button. *hen it is broken# G is to deenergise/ the latch switch opened/ the solenoid relay d under the spring action# the valve returns to its normal position# causing the ram to retract. Is this happening in If not# how can you correct itI Re7enerative )ircuit

>o motion

Bxtension at normal speed (piston moves to right)

apid retraction (pisto

#entre position! The piston does not move. $ight position! etraction. The piston speed is given by %pist & 'pump ()Apist - Arod* where %pist Piston 'peed# m-s Jpump Pump Flow rate# m0-s $pist Piston area# m. $rod od area# m. +eft ,osition! apid Bxtension $pist %pist : Jpump K ($pist 7 $rod) %pist ::L %pist & 'pump(Arod $ small rod area leads to very rapid extension.

,/L H1*T/04 In a hydraulic system# the power is transmitted by pushing the working fluid (usually oil) through the circuit. Duri some of the power is spent in heating the oil. For example# when oil is pushed through a valve# no external work pump still has to exert effort to push the oil through the pressure differential over the valve. ,ou can think of this

the oil and all of it is converted into heat9

The work is done on the oil is given by This is converted into heat and the resultant temperature increase for the oil volume can be calculated by