Hydraulic Actuators:

Cylinders
POWER CONVERSION IN HYDRULIC SYSTEM
Objectives
Describe the construction and operation of basic
hydraulic cylinders, limited-rotation actuators, and
motors.
Compare the design and operation of various types of
hydraulic cylinders.
Select appropriate cylinder design options available for
mounting hydraulic cylinders and reducing hydraulic
shock.
Compare the design and operation of various types of
hydraulic motors.
Objectives
Contrast the operation of fixed- and variable-speed
hydraulic motors.
Describe the construction and operation of a basic
hydrostatic transmission.
Size hydraulic cylinders and motors to correctly meet
system force and speed requirements.
Interpret manufacturer specifications for hydraulic
cylinders.
ACTUATORS
Hydraulic systems are used to control & transmit power
A pump driven by prime mover (electric motor) creates flow
of fluid.
An actuator is used to convert the energy of the fluid back
into mechanical power
Amount of output power developed depends upon the flow
rate, pressure drop across the actuator & its overall
efficiency
TYPES OF ACTUATORS
Linear actuator (hydraulic cylinder)
Provides motion in straight line
Linear displacement depends on stroke length (length of
actuator)
Usually referred to as cylinders, rams (single acting
cylinders) or jacks (cylinder used for lifting)
Rotary actuators (Hydraulic motors)
Produces continuous rotational motion
Pump shaft is rotated to generate flow, a motor shaft is
caused to rotate by fluid being forced into the driving
chambers
ACTUATORS
Semi rotary actuators
Produces non-continuous rotational motion
Limited to less than one revolution (<360)
Used to produce oscillatory motions in mechanisms
LINEAR HYDRAULIC ACTUATORS (CYLINDERS)
Common Types
Single acting cylinder
Double acting cylinder
Displacement cylinder
Special Types
1. Plunger or ram 2.Telescoping
3.Cable 4.Diaphragm
5.Bellow 6.Tandem
7.Duplex 8.Rotary
SINGLE ACTING CYLINDER
OPERATION OF SINGLE ACTING CYLINDER
OPERATION OF SINGLE ACTING CYLINDER
Produces linear motion in one direction
Consists of cylinder (barrel), piston, piston-rod (ram)
& inlet port at piston end or blank end (other end is
known as rod end)
Cylinder is machined to high surface finish (honing)
Fluid enters through inlet port into piston end or
blank end pressure build up-force generation on
piston-movement of piston EXTENSION or
FORWARD STROKE
RETRACTION or RETURN by compression spring or under
the influence of gravity (only in case of vertical mounting)
Usage of seals Piston seal (imparts clearance between
piston & cylinder for clear movement), Rod seal or End seal
(prevention of leakage from cylinder), Bearing (supports
piston rod) & Wiper (prevention of dirt/dust entry into the
cylinder)
Drain hole helps in removing the leaked oil across piston
seal
Widely used in hydraulic systems
DOUBLE ACTING CYLINDER
DOUBLE ACTING CYLINDER
DOUBLE ACTING CYLINDER
Produces linear motion in two directions
May be single rod ended or double rod ended
Piston is connected to smaller diameter piston rod
Fluid pressure acts on either side of piston alternatively
Both sides of piston has oil ports
Parts of double acting cylinder
Fluid enters through left port causing extension stroke
while when it enters through right port causes retraction
stroke, for present case
For a given pressure double acting cylinder (single rod
type) exerts greater force when extending than when
retracting
CONSTRUCTIONAL FEATURES OF CYLINDER
CONSTRUCTIONAL FEATURES OF DOUBLE ACTING CYLINDER
Five basic parts Base cap & Bearing cap with port
connections, a cylinder barrel, piston & piston rod
End caps are secured to barrel through welding or threaded
connection
Smooth inner surface of barrel (seamless drawn tube) to
prevent wear & leakage
Pistons (separates high & low pressure zones) are usually
made of cast iron or steel
Function of End seal, bearing & wiper seal
DOUBLE ROD CYLINDER
DOUBLE ROD CYLINDER
Consists of two rods
It is of double acting type
Suitable for extracting work from both sides at a time
For the same rod diameters force remains same
Used when required to exert equal forces & speed in both
directions
This type of cylinder is center mounted and is normally used
when the same task is performed at either end on staggered
cycles
TANDEM CYLINDER
TANDEM CYLINDER
Also known as combination cylinder
Two separate pistons are mounted on same rod
Two double acting cylinders are connected in series
Suitable for higher force (2 cylinders twice force)
generation with smaller cylinders
High volume of oil is required to drive the cylinders
TELESCOPIC CYLINDER
TELESCOPIC CYLINDER
Multiple cylinders mounted concentrically within one another
Suitable for longer strokes with shorter retraction
Operates on displacement principle
Stop rings limit the movement of each section
When the cylinder extends, all the sections move together until
the outer section is prevented from further extension by its stop
ring
Remaining sections continue out-stroking until the second
outermost section reaches the limit of its stroke and so on until all
sections are extended, the innermost one being last of all
For a given input flow rate, the speed of operation will increase in
steps as each successive section reaches the end of its stroke,
For a specific pressure the load lifting capacity reduces for each
successive section
Example : high lift fork truck, tilting of truck dump bodies
Hydraulic Cylinders
Actuators are the components used in a hydraulic
system to provide power to a required work location
Cylinders are the hydraulic system components that
convert fluid pressure and flow into linear mechanical
force and movement
Hydraulic Cylinders
A basic cylinder consists of:
Piston
Piston rod
Barrel
Hydraulic Cylinders
Parts of a typical cylinder
Hydraulic Cylinders
The piston forms sealed, variable-volume chambers in
the cylinder
System fluid forced into the chambers drives the
piston and rod assembly
Linear movement is produced
Hydraulic Cylinders
Seals prevent leakage between:
Piston and cylinder barrel
Piston rod and head
Barrel and its endpieces
Wiper seal, or scraper, prevents dirt and water from
entering the cylinder during rod retraction
Hydraulic Cylinders
Various seals are used in a cylinder
Hydraulic Cylinders
Rod wipers prevent
contamination from
entering on rod
retraction
IMI Norgren, Inc.
Hydraulic Cylinders
Cylinders are typically classified by operating principle
or by construction type
Single-acting or double-acting
Tie rod, mill, threaded end, or one piece
Hydraulic Cylinders
Single- and double-acting cylinders
Single-acting Double-acting
Hydraulic Cylinders
Single-acting cylinders exert force either on extension
or retraction
They require an outside force to complete the second
motion
Hydraulic Cylinders
Double-acting cylinders generate force during both
extension and retraction
Directional control valve alternately directs fluid to
opposite sides of the piston
Force output varies between extension and retraction
Hydraulic Cylinders
Effective piston area is reduced on retraction due to the
rod cross section
Hydraulic Cylinders
Volume is reduced on retraction
Hydraulic Cylinders
External tie rod bolts are used to secure the ends on
the tie-rod cylinder design
Commonly found on heavy industrial machines
External tie rods increase chance of damage and
promote accumulation of dirt
Hydraulic Cylinders
Tie-rod cylinder
Hydraulic Cylinders
Mill cylinders
Yates Industries, Inc.
Hydraulic Cylinders
Threaded-end cylinder
Bailey International Corporation
Hydraulic Cylinders
One-piece cylinder has the cylinder barrel welded to
the ends
Produces a compact actuator
Cost effective to manufacture
Cannot be serviced (throwaway)
Hydraulic Cylinders
Hydraulic ram is commonly used in hand-operated
jacks
Rod is basically the same diameter as the inside of the
cylinder barrel
Large-diameter rod is more rigid under load, but
cylinder can generate force in only one direction
Hydraulic Cylinders
Typical hand-operated
jack
Hydraulic Cylinders
Telescoping cylinders are available for applications
requiring long extension distances
Rod is made up of several tubes of varying size nested
inside of the barrel
Each tube extends, producing a rod longer than the
cylinder barrel
Typical example is the actuator that raises the box on a
dump truck
Hydraulic Cylinders
Telescoping cylinders
Star Hydraulics, Inc.
Hydraulic Cylinders
Cylinders often use hydraulic cushions
Provide a controlled approach to the end of the stroke
Reduces the shock of the impact as the piston contacts
the cylinder head
Hydraulic Cylinders
Cylinder cushioning device
Hydraulic Cylinders
A variety of mounting configurations are used to
attach the cylinder body and rod end to machinery
Fixed centerline
Fixed noncenterline
Pivoting centerline
Expected cylinder loading is the major factor in the
selection of the mounting style
Hydraulic Cylinders
Head-end flange mount
Hydraulic Cylinders
Fixed-noncenterline mount
Hydraulic Cylinders
Pivoting-centerline, clevis mount
Hydraulic Cylinders
Pivoting-centerline, trunnion mount
Hydraulic Cylinders
The force generated by a cylinder is calculated by
multiplying the effective area of the piston by the
system pressure
Hydraulic Cylinders
Effective cylinder piston area
Hydraulic Cylinders
Force generated during the extension of a double-
acting cylinder with a single-ended rod is calculated
as:
Ef = Sp Pa
where:
Ef = extension force
Sp = system pressure
Pa = piston area
(Calculations require consistent units of measure
in these formulas)
Hydraulic Cylinders
Force generated during the retraction of a double-
acting cylinder with a single-ended rod is calculated
as:
Rf = Sp (Pa Ra)
where:
Rf = retraction force
Sp = system pressure
Pa = piston area
Ra = rod area
Hydraulic Cylinders
Speed at which the cylinder extends or retracts is
determined by:
Physical volume per inch of cylinder piston travel
Amount of fluid entering the cylinder
Effective area of the piston is used to calculate the
volume of the cylinder per inch of piston travel
Hydraulic Cylinders
Extension speed of a double-acting cylinder with a
single-ended rod is calculated as:
Es = Fr (Cg Pa)
where:
Es = extension speed
Fr = flow delivery rate
Cg = cubic inches in one gallon
Pa = piston area
Hydraulic Cylinders
Calculate retraction speed of a double-acting cylinder
with single-ended rod as:
Rs = Fr [Cg (Pa Ra)]
where:
Rs = retraction speed
Fr = flow delivery rate
Cg = cubic inches in one gallon
Pa = piston area
Ra = rod area
Hydraulic Cylinders
Flow rate to produce a desired extension or retraction
speed is calculated as:
Fr = (Ea Cs) Cg
where:
Fr = system flow rate
Ea = effective piston area
Cs = cylinder speed
Cg = cubic inches in one gallon
Hydraulic Cylinders
Hydraulic cylinder manufacturers provide detailed
specifications concerning:
Construction
Physical size
Load capacity
Hydraulic Cylinders
This information includes basic factors such as:
Bore
Stroke
Pressure rating
Other details, such as service rating, rod end
configurations, and dimensions
Hydraulic Cylinders
Typical manufacturers catalog page
Bailey International Corporation
Limited-Rotation
Hydraulic Actuators
Limited-rotation devices are actuators with an output
shaft that typically applies torque through
approximately 360 of rotation
Models are available that are limited to less than one
revolution, while others may produce several
revolutions
Limited-Rotation
Hydraulic Actuators
Most common designs of limited-rotation actuators
are:
Rack-and-pinion
Vane
Helical piston and rod
Limited-Rotation
Hydraulic Actuators
Rack-and-pinion limited rotation actuator
IMI Norgren, Inc.
Limited-Rotation
Hydraulic Actuators
Vane limited-rotation actuator
Limited-Rotation
Hydraulic Actuators
Helical piston and rod limited-rotation actuator
Limited-Rotation
Hydraulic Actuators
Limited-rotation actuators are used to perform a
number of functions in a variety of industrial
situations
Indexing devices on machine tools
Clamping of workpieces
Operation of large valves
Limited-Rotation
Hydraulic Actuators
Limited-rotation actuators are used in this robotic arm
IMI Norgren, Inc.