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Sales Industry Sector Metallurgy
Formulary Hydraulics
30.08.2011 1
Hydraulic Formulary

Author: Houman Hatami
Tel.: +49-9352-18-1225
Fax: +49-9352-18-1293
houman.hatami@boschrexroth.de


30.08.2011 2

CONTENTS

RELATIONS BETWEEN UNITS............................................................................................................. 4
IMPORTANT CHARACTERISTIC VALUES OF HYDRAULIC FLUIDS................................................ 6
GENERAL HYDRAULIC RELATIONS................................................................................................... 7
PISTON PRESSURE FORCE ...................................................................................................................... 7
PISTON FORCES..................................................................................................................................... 7
HYDRAULIC PRESS................................................................................................................................. 7
CONTINUITY EQUATION........................................................................................................................... 8
PISTION SPEED....................................................................................................................................... 8
PRESSURE INTENSIFIER.......................................................................................................................... 8
HYDRAULIC SYSTEM COMPONENT................................................................................................... 9
HYDRO PUMP......................................................................................................................................... 9
HYDRO MOTOR....................................................................................................................................... 9
Hydro motor variable...................................................................................................................... 10
Hydro motor fixed........................................................................................................................... 11
Hydro motor intrinsic frequency ..................................................................................................... 12
HYDRO PISTON..................................................................................................................................... 13
Differential piston............................................................................................................................ 14
Double acting cylinder .................................................................................................................... 15
Cylinder in differential control ......................................................................................................... 16
Cylinder intrinsic frequency at differential cylinder......................................................................... 17
Cylinder intrinsic frequency at double acting cylinder .................................................................... 18
Cylinder intrinsic frequency at plunger cylinder ............................................................................. 19
PIPING................................................................................................................................................... 20
APPLICATION EXAMPLES FOR SPECIFICATION OF THE CYLINDER PRESSURES AND
VOLUME FLOWS UNDER POSITIVE AND NEGATIVE LOADS........................................................ 21
DIFFERENTIAL CYLINDER EXTENDING WITH POSITIVE LOAD..................................................................... 22
DIFFERENTIAL CYLINDER RETRACTING WITH POSITIVE LOAD................................................................... 23
DIFFERENTIAL CYLINDER EXTENDING WITH NETAGIVE LOAD.................................................................... 24
DIFFERENTIAL CYLINDER RETRACTING WITH NEGATIVE LOAD.................................................................. 25
DIFFERENTIAL CYLINDER EXTENDING AT AN INCLINED PLANE WITH POSITIVE LOAD .................................. 26
DIFFERENTIAL CYLINDER RETRACTING AT AN INCLINED PLANE WITH POSITIVE LOAD................................. 27
DIFFERENTIAL CYLINDER EXTENDING AT AN INCLINED PLANE WITH NEGATIVE LOAD ................................ 28
DIFFERENTIAL CYLINDER RETRACTING AT AN LINCLINED PBLANE WITH NEGATIVE LOAD............................ 29
HYDRAULIC MOTOR WITH POSITIVE LOAD............................................................................................... 30
HYDRAULIC MOTOR WITH NEGATIVE LOAD.............................................................................................. 31
IDENTIFICATION OF THE REDUCED MASSES OF DIFFERENT SYSTEMS................................... 32
LINEARE DRIVES .................................................................................................................................. 33
Primary applications (Energy method) ........................................................................................... 33
Concentrated mass at linear movements....................................................................................... 35
Distributed mass at linear movements........................................................................................... 36
ROTATION............................................................................................................................................ 37
COMBINATION OF LINEAR AND ROTATIONAL MOVEMENT.......................................................................... 38
HYDRAULIC RESISTANCES...39
ORIFICE EQUATION............................................................................................................................... 39
TROTTLE EQUATION.............................................................................................................................. 39


30.08.2011 3

HYDRO ACCUMULATOR.................................................................................................................... 40
HEAT EXCHANGER (OIL- WATER).................................................................................................... 41
LAYOUT OF A VALVE......................................................................................................................... 43


30.08.2011 4
Relation between Units
Size Unit Symbol Relation

Lengths Micrometer
Millimeter
Centimeter
Decimeter
Meter
Kilometer
m
mm
cm
dm
m
km
1m = 0,001mm
1mm = 0,1cm = 0,01dm = 0,001m
1cm = 10mm = 10.000m
1dm = 10cm = 100mm = 100.000m
1m = 10dm = 100cm = 1.000mm = 1.000.000m
1km = 1.000m = 100.000cm = 1.000.000mm

Surfaces Square centimeter
Square decimeter
Square meter
Are
Hectare
Square kilometer
cm
2
dm
2

m
2
a
ha
km
2

1cm
2
= 100mm
2
1dm
2
= 100cm
2
= 10.000mm
2

1m
2
= 100dm
2
= 10.000cm
2
= 1.000.000mm
2
1a = 100m
2

1ha = 100a = 10.000m
2

1km
2
= 100ha = 10.000a = 1.000.000m
2

Volume Cubic centimeter
Cubic decimeter
Cubic meter
Milliliter
Liter
Hectoliter
cm
3

dm
3

m
3

ml
l
hl
1cm
3
= 1.000mm
3
= 1ml = 0,001l
1dm
3
= 1.000cm
3
= 1.000.000mm
3

1m
3
= 1.000dm
3
= 1.000.000cm
3
1ml = 0,001l = 1cm
3

1l = 1.000 ml = 1dm
3

1hl = 100l = 100dm
3

Density Gram/
Cubic centimeter
g
cm
3

1 1 1 1
3 3 3
g
cm
kg
dm
t
m
g
ml
= = =

Force
Weight
Newton N
1 1 1
2
N
kg m
s
J
m
=
-
=

1daN = 10N

Torque Newton meter Nm 1Nm = 1J

Pressure Pascal
Bar
2
inch
pound
psi =

2
cm
kp

Pa
Bar

Psi

1Pa = 1N/m
2
= 0,01mbar =
1
2
kg
m s -

Pa
m
N
cm
N
bar
5
2 2
10 000 . 100 10 1 = = =

1psi = 0,06895 bar
bar
cm
kp
981 , 0 1
2
=


30.08.2011 5

Mass Milligram
Gram
Kilogram
Ton
Mega gram
mg
g
kg
t
Mg
1mg = 0,001g
1g = 1.000mg
1kg = 1000g = 1.000.000 mg
1t = 1000kg = 1.000.000g
1Mg = 1t

Acceleration Meter/
per square second
m
s
2

1 1
2
m
s
N
kg
=

1g = 9,81 m/s
2

Angular speed One/ Second
Radiant/ Second
1
s

rad
s

e = 2-t-n n in 1/s

Power Watt
Newton meter/ second
Joule/ second
W
Nm/s
J/s
1 1 1 1
2
W
Nm
s
J
s
kg m
s
m
s
= = =
-
-

Work/ Energy
Heat volume
Watt second
Newton meter
Joule
Kilowatt hour
Kilo joule
Mega joule
Ws
Nm
J
kWh
kJ
MJ
1Ws 1Nm 1
kg m
s
m 1J
2
= =
-
- =

1kWh = 1.000 Wh = 1000-3600Ws = 3,6-10
6
Ws
= 3,6-10
3
kJ = 3600kJ = 3,6MJ

Mechanic
tension
Newton/ square
millimeter
N
mm
2

1 10 1
2
N
mm
bar MPa = =

Plane angle Second
Minute
Degree
Radiant

rad
1 = 1/60
1 = 60
1= 60 = 3600 =
t
180
rad

1rad = 1m/m = 57,2957
1rad = 180/t

Speed One/second
One/minute
1/s
1/min
1
60
1 1
s
s = =

min

1 1
60
1
min
min = =
s


30.08.2011 6

Important Characteristic Values of Hydraulic Fluids

HLP HFC HFA
(3%)
HFD
Density at 20C

[kg/cm
3
]
0,00087 0,00105-0,00108 0,0001 0,000115
Kinematic Viscosity
at 40C

[mm
2
/s]
10-100 36-50 0,7 15-70
Compressions Module E
at 50C

[Bar]
12000-14000

20400-23800 15000-
17500
18000-
21000
Specific Heat at 20C

[kJ/kgK]
2,1 3,3 4,2 1,3-1,5
Thermal Conductivity at 20C

[W/mK]
0,14 0,4 0,6 0,11
Optimal Temperatures

[C]
40-50 35-50 35-50 35-50
Water Content

[%]
0 40-50 80-97 0
Cavitation Tendency low high very high low


30.08.2011 7
General Hydraulic Relations
Piston Pressure Force
Figure Equation / Equation Variations Symbols / Units

A p F - - =10
F p A = - -q - 10
A
d
=
-
2
4
t

p
F
d
-
- -
=
t
1 , 0 4

2
4
1 , 0
d
F
p
-
-
- =
t

F = piston pressure force[N]
p = fluid pressure[bar]
A = piston surface[cm
2
]
d = piston diameter[cm]
q = efficiency cylinder
Piston Forces

10 - - = A p F
e

10 - - - = q A p F
e

A
d
=
-
2
4
t

A For annulus surface:
A
D d
=
- ( )
2 2
4
t

F = piston pressure force[N]
p
e
= excess pressure on the piston[bar]
A = effective piston surface[cm
2
]
d = piston diameter[cm]
q = efficiency cylinder
Hydraulic Press


F
A
F
A
1
1
2
2
=
F s F s
1 1 2 2
- = -

1
2
2
1
2
1
s
s
A
A
F
F
= = =

F
1
= Force at the pump piston[N]
F
2
= Force at the operating piston[N]
A
1
= Surface of the pump piston [cm
2
]
A
2
= Surface of the operating piston [cm
2
]
s
1
= Stroke of the pump piston [cm]
s
2
= Stroke of the operating piston [cm]
= Gear ratio


30.08.2011 8
Continuity Equation

Q Q
1 2
=
Q A v
1 1 1
= -
Q A v
2 2 2
= -
A v A v
1 1 2 2
- = -

Q
1,2
= Volume flows [cm
3
/s, dm
3
/s, m
3
/s]
A
1,2
= Area surfaces [cm
2
, dm
2
, m
2
]
v
1,2
= Velocities
[cm/s, dm/s, m/s]

Piston Speed

v
Q
A
1
1
1
=
v
Q
A
2
2
2
=
A
d
1
2
4
=
-t

A
D d
2
2 2
4
=
- ( ) t

v
1,2
= Piston speed [cm/s]
Q
1,2
= Volume flow [cm
3
/s]
A
1
= Effective piston surface (circle) [cm
2
]
A
2
= Effective piston surface (ring) [cm
2
]
Pressure Intensifier

p A p A
1 1 2 2
- = -

p
1
= Pressure in the small cylinder [bar]
A
1
= Piston surface [cm
2
]
p
2
= Pressure at the large cylinder [bar]
A
2
2
]


30.08.2011 9
Hydraulic System Components
Hydro Pump

Q
V n
vol
=
- -q
1000
[l/min]
P
p Q
an
ges
=
-
- 600 q
[kW]
M
V p
mh
=
- -
-
159
100
, A
q
[Nm]
q q q
ges vol mh
= -
Q = Volume flow [l/min]
V = Nominal volume [cm
3
]
n = Drive speed of the pump [min
-1
]
P
an
= Drive power [kW]
p = Service pressure [bar]
M = Drive torque [Nm]
q
ges
= Total efficiency (0,8-0,85)
q
vol
= Volumetric efficiency (0,9-0,95)
q
mh
= Hydro-mechanic efficiency(0,9-0,95)

Hydro Motor

Q
V n
vol
=
-
- 1000 q

n
Q
V
vol
=
- - q 1000

2
10 59 , 1
20
- - A - - =
-
- - A
=
mh
mh
ab
p V
V p
M q
t
q

P
p Q
ab
ges
=
- - A q
600

Q = Volume flow [l/min]
V = Nominal volume [cm
3
]
n = Drive speed of the pump [min
-1
]
q
ges
= Total efficiency (0,8-0,85)
q
vol
= Volumetric efficiency (0,9-0,95)
q
mh
= Hydro-mechanic efficiency
(0,9-0,95)
Ap = Pressure difference between motor inlet and
outlet (bar)
P
ab
= Output power of the motor [kW]
M
ab
= Output torque [Nm]


30.08.2011 10
Hydro Motor Variable

M
P
n
d
= -
30000
t

P M n
d
= - -
t
30000

n
P
M
d
= -
30000
t

M
M
i
d
d
Getr
=
-
max
q

n
n
i
=
max

Ap
M
V
d
g mh
= -
-
20t
q

Q
V n
g
vol
=
-
- 1000 q

Q
V n
P
g vol
=
- -q
1000

P
Q p
ges
=
-
-
A
600 q

M
d
= Torque [Nm]
P = Power [kW]
n = Speed [min
-1
]
M
dmax
= Max torque [Nm]
i = Gear ratio
q
Getr
= Gear efficiency
q
mh
= Mech./hydraulic efficiency
q
vol
= Vol. efficiency
V
g
= Flow volume [cm
3
]


30.08.2011 11
Hydro Motor Fixed

M
P
n
d
= -
30000
t

P M n
d
= - -
t
30000

n
P
M
d
= -
30000
t

M
M
i
d
d
Getr
=
-
max
q

n
n
i
=
max

Ap
M
V
d
g mh
= -
-
20t
q

Q
V n
g
vol
=
-
- 1000 q

Q
V n
P
g vol
=
- -q
1000

P
Q p
ges
=
-
-
A
600 q

M
d
= Torque [Nm]
P = Power [kW]
n = Speed [min
-1
]
M
dmax
= Max torque [Nm]
i = Gear ratio
q
Getr
= Gear efficiency
q
mh
= Mech./hydraulic efficiency
q
vol
= Vol. efficiency
V
g
= Flow volume [cm
3
]


30.08.2011 12
Hydro Motor Intrinsic Frequency

e
t
0
2
2
2
2
=
-
-
+
E
J
V
V
V
red
G
G
R
( )
( )

f
0
0
2
=
e
t

V
G
= Displacement [cm
3
]
e
0
= Intrinsic angular frequency [1/s]
f
0
= Intrinsic frequency [Hz]
J
red
= Moment of inertia red. [kgm
2
]

E
l
= 1400 N/mm
2
V
R
= Volume of the line [cm
3
]


30.08.2011 13
Hydro Cylinder

A
d d
=
-
=
-
1
2
1
2
400
0 785
100
t ,
[cm
2
]
A
d
st
=
-
2
2
0 785
100
,
[cm
2
]
A
d d
R
=
- ( ) ,
1
2
2
2
0 785
100
[cm
2
]
10000
785 , 0
2
1
- -
=
d p
F
D
[kN]
F
p d d
z
=
- - ( ) ,
1
2
2
2
0 785
10000
[kN]
v
h
t
Q
A
=
-
=
- 1000 6
[m/s]
60 6 - = - - =
t
V
v A Q
th
[l/min]

Q
Q
th
vol
=
q
.

V
A h
=
-
10000
[l]
t
A h
Q
=
- -
-
6
1000
[s]
d
1
= Piston diameter [mm]
d
2
= Piston rod diameter [mm]
p = Service pressure [bar]
v = Stroke speed [m/s]
V = Stroke volume [l]
Q = Volume flow, considering the leakages
(l/min)
Q
th
= Volume flow, without considering the
leakages (l/min)
q
vol
= Volumetric efficiency (approx. 0,95)
h = Stroke [mm]
t = Stroke time [s]
F
D
F
Z
F
S


30.08.2011 14
Differential Cylinder

d
F
p
K
D
K
= -
-
-
100
4
t

p
F
d
K
D
K
=
- -
-
4 10
4
2
t

p
F
d d
St
Z
K St
=
- -
-
4 10
4
2 2
t ( )

d
K
d
st
= Rod diameter [mm]
F
D
= Pressure force [kN]
F
z
= Traction force [kN]
p
K
= Pressure at the piston side [bar]
= Aspect ratio
Q
K
= Volume flow piston side [l/min]
Q
St
= Volume flow rod side [l/min]
=
d
d d
K
K St
2
2 2
( )

Q v d
K a K
=
-
- -
6
400
2
t

Q v d d
St e K St
=
-
- -
6
400
2 2
t
( )
v
Q
d d
e
St
K St
=
-
6
400
2 2
t
( )

v
Q
d
a
K
K
=
-
6
400
2
t

Vol d h
p St
=
-
- -
t
4 10
6
2

Vol h d d
F K St
=
-
- -
t
4 10
6
2 2
( )
v
a
= Extending speed [m/s]
v
e
= Retracting speed [m/s]
Vol
p
= Working volume [l]
Vol
F
= Fill-up volume [l]
h = Stroke [mm]


30.08.2011 15
Double Acting Cylinder

p
F
d d
A
A
K StA
=
-
-
4 10
4
2 2
t ( )

p
F
d d
B
B
K StB
=
-
-
4 10
4
2 2
t ( )

Q v d d
A a K StA
=
-
- -
6
400
2 2
t
( )
Q v d d
B b K StB
=
-
- -
6
400
2 2
t
( )
v
Q
d d
e
St
K St
=
-
6
400
2 2
t
( )

v
Q
d
a
K
K
=
-
6
400
2
t

Vol d h
p St
=
-
- -
t
4 10
6
2

Vol h d d
FA K StA
=
-
- -
t
4 10
6
2 2
( )
Vol h d d
FB K StB
=
-
- -
t
4 10
6
2 2
( )
d
K
d
stA
= Rod diameter A-side [mm]
d
stB
= Rod diameter B-side [mm]
F
A
= Force A [kN]
F
B
= Force B [kN]
p
A
= Pressure at the A-side [bar]
p
B
= Pressure at the B-side [bar]
Q
A
= Volume flow A-side [l/min]
Q
B
= Volume flow B-side [l/min]
v
a
= Speed a [m/s]
v
b
= Speed b [m/s]
Vol
p
= Compensating volume [l]
Vol
FA
= Fill-up volume A [l]
Vol
FB
= Fill-up volume B [l]


30.08.2011 16
Cylinder in Differential Control

St
D
st
p
F
d
-
-
- =
t
4
100
p
F
d
K
D
St
=
- -
-
4 10
4
2
t

p
F
d d
St
Z
K St
=
- -
-
4 10
4
2 2
t ( )

Q v d
a St
=
-
- -
6
400
2
t

d
K
d
st
= Rod diameter [mm]
F
D
= Pressure force [kN]
F
z
= Traction force [kN]
p
K
= Pressure at the piston side [bar]
p
St
= Pressure at the rod side [bar]
h = Stroke [mm]
Q
K
= Volume flow piston side [l/min]
Q
St
= Volume flow rod side [l/min]
Extension:
v
Q
d
a
P
St
=
-
6
400
2
t

Q
Q d
d
K
P K
St
=
-
2
2

Q
Q d d
d
St
P K St
St
=
- ( )
2 2
2

Retraction:
v
Q
d d
e
P
K St
=
-
6
400
2 2
t
( )

Q
St
=Q
P
Q
Q d
d d
K
P K
K St
=
-
2
2 2
( )

Vol d h
p St
=
-
- -
t
4 10
6
2

Vol h d d
F K St
=
-
- -
t
4 10
6
2 2
( )
Q
P
= Pump flow [l/min]
v
a
= Extending speed [m/s]
v
e
= Retracting speed [m/s]
Vol
p
= Working volume [l]
Vol
F
= Fill-up volume [l]


30.08.2011 17
Cylinder Intrinsic Frequency at Differential Cylinders

A
d
K
K
=
2
4
100
t

A
d d
R
K St
=
( )
2 2
4
100
t

V
d L
RK
RK K
= -
2
4 1000
t

V
d L
RSt
RSt St
= -
2
4 1000
t

m
V
RK
RK l
=
-
1000

m
V
RSt
RSt l
=
-
1000

)
1 1
(
3 3 3
K R
K
RK
R
RSt
R
R
k
A A
A
V
A
V
A
h A
h
+
|
|
.
|
\
|
+ +
-
=
)
10 10
(
1
2 2
0
RSt
K R
l R
RK
K K
L K
V
h h A
E A
V
h A
E A
m
+
-
-
+
+
-
-
- = e

f
0
0
2
=
e
t

m m
d
d
m
d
A
lred RK
K
RK
RSt
RSt
R
=
|
\
|
.
| +
-
|
\
|
.
|
4
1 400
t

A
K
2
]
A
R
= Piston ring surface [cm
2
]
d
K
d
St
d
RK
= NW- piston side [mm]
L
K
= Length of piston side [mm]
d
RSt
= NW-rod side [mm]
L
St
= Length of rod side [mm]
h = Stroke [cm]
V
RK
= Volume of the line piston side [cm
3
]
V
RSt
= Volume of the line rod side [cm
3
]
m
RK
= Mass of the oil in the line piston side [kg]
m
RSt
= Mass of the oil in the line rod side [kg]
h
K
= Position at min intrinsic frequency [cm]
f
0
= Intrinsic frequency [Hz]
0
e = Angular frequency

e e
01 0
= -
+
m
m m
red
lred red

f
01
01
2
=
e
t


30.08.2011 18
Cylinder Intrinsic Frequency at Double Acting Cylinders

A
d d
R
K St
=
( )
2 2
4
100
t

V
d L
R
RK K
= -
2
4 1000
t

m
V
R
R l
=
-
1000

e
0
2
100
2
10
= -
-
-
-
+
E
m
A
A h
V
l
red
R
R
RSt
( )
f
0
0
2
=
e
t

m m
d
A
lred RK
R
R
= -
-
|
\
|
.
| 2
1 400
4
t

e e
01 0
= -
+
m
m m
red
lred red

f
01
01
2
=
e
t

A
R
= Piston ring surface [cm
2
]
d
K
d
St
d
R
= NW [mm]
L
K
= Length of the piston side [mm]
h = Stroke [mm]
V
R
3
]
m
R
= Mass of the oil in the line [kg]
f
0
= Intrinsic frequency
0


30.08.2011 19
Cylinder Intrinsic Frequency for Plunger Cylinders

A
d
K
K
=
2
4
100
t

V
d L
R
K K
= -
2
4 1000
t

m
V
R
R l
=
-
1000

) ( 100
2
0
RSt K
K
red
l
V h A
A
m
E
+ -
- - = e
f
0
0
2
=
e
t

m m
d
d
lred R
K
R
= -
|
\
|
.
|
2
4

e e
01 0
= -
+
m
m m
red
lred red

f
01
01
2
=
e
t

A
K
2
]
d
K
d
R
= Diameter of the piping [mm]
L
K
= Length piston side [mm]
L
R
= Length of the line [mm]
h = Stroke [mm]
V
R
3
]
M
R
= Mass of the oil in the line [kg]
f
0
= Intrinsic frequency
0


30.08.2011 20
Piping

Ap
l v
d
= -
- - -
-

2
10
2

lam.
Re
=
64

4
.
Re
316 , 0
=
turb

Re =
-
-
v d
u
10
3

v
Q
d
=
- -
-
6
4
10
2
2
t

d
Q
v
=
-
-
400
6 t

Ap = Pressure loss at direct piping [bar]
= Density [kg/dm
3
] (0,89)
= Pipe friction coefficient
lam.
= Pipe friction coefficient for laminar flow
turb.
= Pipe friction coefficient for turbulent flow
l = Length of the line [m]
v = Velocity in the line [m/s]
d = Internal diameter of the piping [mm]
v = Kinematic viscosity [mm
2
/s]
Q = Volume flow in the piping [l/min]


30.08.2011 21
Application Examples for Specification of the Cylinder Pressures
and Volume Flows under Positive and Negative Load

Nomenclature
Parameters Symbols Units
Acceleration / deceleration A m/s
2

Cylinder surface A
1
cm
2

Ring surface A
2
cm
2

Aspect ratio
=A
1
/A
2

-
Total force F
T
daN
Acceleration force F
a
=0,1-m-a daN
External forces F
E
daN
Friction forces (coulomb friction) F
C
daN
Sealing friction force F
R
daN
Weight force G daN
Mass
m
G
g
m
K
= +

kg
Piston mass m
K
kg
Volume flow Q=0,06-A-v
max
v
max

l/min
cm/s
Torque T=o-J+ T
L
Nm
Load torque T
L
Nm
Angular acceleration o rad/s
2

Inertia moment J kgm
2


30.08.2011 22
Differential Cylinder Extending with Positive Load

Layout:
F
T
= F
a
+F
R
+F
C
+F
E [daN]
Given Parameters
F
T
= 4450 daN
P
S
= 210 bar
P
T
= 5,25 bar
A
1
= 53,50 cm2
A
2
= 38,10 cm2
= 1,40
v
max
= 30,00 cm/s
==> p
1
und p
2

) 1 (
)] ( [
3
2
2
2
2
1
+
+ +
=
A
A p F R A p
p
T T S
bar
2
1
2
p p
p p
S
T
+ = bar
Verification of the cylinder dimensioning and
calculation of the nominal volume flow Q
N
,
depending on the load pressure p
1
.
Q= 0,06-A
1
-v
max
l/min
Q Q
p p
N
S
=
35
1
l/min

Selection of a Servo valve 10% larger than the
calculated nominal volume flow.

Calculation:
p bar
1
2
3
210 38 1 1 4 4450 5 25 38 1
38 1 1 1 4
120 =
- + + -
+
=
, , [ ( , , )]
, ( , )

p bar
2 2
5 25
210 120
1 4
52 = +

= ,
,

Q= 0,06-53,5-30=96 l/min

Q l
N
=
= 96
35
210 120
60 / min


30.08.2011 23
Differential Cylinder Retracting with Positive Load

Layout:
F
T
= F
a
+F
R
+F
C
+F
E [daN]
Given Parameters
F
T
= 4450 daN
P
S
= 210 bar
P
T
= 5,25 bar
A
1
= 53,50 cm2
A
2
= 38,10 cm2
= 1,40
v
max
= 30,00 cm/s
==> p
1
und p
2

) 1 (
)] ( ) (
3
2
2
3
2
2

+
+ +
=
A
A p F A p
p
T T S
bar
] ) [(
2
2 1
p p p p
S T
+ = bar
N
,
1
.
Q= 0,06-A
2
-v
max
l/min
Q Q
p p
N
S
=
35
2
l/min

Calculation:
p bar
2
2
3
210 381 14 4450 525 381 14
3811 14
187 =
- - + + - -
+
=
( , , ) ( , , , )]
, ( , )

p bar
1
2
5 25 210 187)1 4 52 = + = , [( , ]

Q= 0,06-38,1-30=69 l/min

Q l
N
=
= 96
35
210 187
84 / min


30.08.2011 24
Differential Cylinder Extending with Negative Load

Layout:
F
T
= F
a
+F
R
-G
[daN]
Given Parameters
F
T
= -2225 daN
P
S
= 175 bar
P
T
= 0 bar
A
1
= 81,3 cm
2

A
2
= 61,3 cm
2

= 1,3
v
max
= 12,7 cm/s
==> p
1
und p
2

) 1 (
)] ( [
3
2
2
2
2
1
+
+ +
=
A
A p F A p
p
T T S
bar
2
1
2
p p
p p
S
T
+ = bar
N
,
1
.
Q= 0,06-A
1
-v
max
l/min
Q Q
p p
N
S
=
35
1
l/min

Calculation:
p bar
1
2
3
175 61 3 1 3 2225 0 61 3
61 3 1 1 3
36 =
- + + -
+
=
, , [ ( , )]
, ( , )

p bar
2 2
0
175 36
1 3
82 = +

=
,

Q= 0,06-81,3-12,7=62 l/min

Q l
N
=
= 62
35
175 36
31 / min


30.08.2011 25
Differential Cylinder Retracting with Negative Load

Layout:
F
T
= F
a
+F
R
-G
[daN]
Given Parameters
F
T
= -4450 daN
P
S
= 210 bar
P
T
= 0 bar
A
1
= 81,3 cm
2

A
2
= 61,3 cm
2

= 1,3
v
max
= 25,4 cm/s
==> p
1
und p
2

) 1 (
)] ( ) (
3
2
2
3
2
2

+
+ +
=
A
A p F A p
p
T T S
bar
] ) [(
2
2 1
p p p p
S T
+ = bar
N
,
1
.
Q= 0,06-A
2
-v
max
l/min
Q Q
p p
N
S
=
35
2
l/min

Calculation:
p bar
2
2
3
210 613 13 4450 0 613 13
6131 13
122 =
- + + - -
+
=
( , , ) ( , , )]
, ( , )

p bar
1
0 210 122 149 = + = [( )]

Q= 0,06-61,3-25,4=93 l/min

Q l
N
=
= 93
35
210 122
59 / min


30.08.2011 26
Differential Cylinder Retracting at an Inclined Plane with Positive Load

Layout:
F
T
= F
a
+F
E
+F
S
+[G-(-coso+sino)] daN

Given Parameters
F
T
= 2225 daN
P
S
= 140 bar
P
T
= 3,5 bar
A
1
= 31,6 cm
2

A
2
= 19,9 cm
2

R = 1,6
v
max
= 12,7 cm/s
==> p
1
and p
2

) 1 (
)] ( [
3
2
2
2
2
1
+
+ +
=
A
A p F A p
p
T S
bar
2
1
2
p p
p p
S
T
+ = bar
N
,
1
.
Q= 0,06-A
1
-v
max
l/min
Q Q
p p
N
S
=
35
1
l/min

Calculation:
p bar
1
2
3
140 199 16 2225 35 199
199 1 16
85 =
- + + -
+
=
( , ) , [ ( , , )]
, ( , )

p bar
2 2
35
140 85
1 6
25 = +

=
,

Q= 0,06-31,6-12,7=24 l/min
Q
N
=
= 24
35
140 85
19
l/min


30.08.2011 27
Differential Cylinder Retracting at an Inclined Plane with Positive Load

Layout:
F
T
=F
a
+F
E
+F
S
+[G-(-coso+sino)] daN

Given Parameters
F
T
= 1780 daN
P
S
= 140 bar
P
T
= 3,5 bar
A
1
= 31,6 cm
2

A
2
= 19,9 cm
2

= 1,6
v
max
= 12,7 cm/s
==> p
1
and p
2

) 1 (
)] ( ) (
3
2
2
3
2
2

+
+ +
=
A
A p F A p
p
T S
bar
] ) [(
2
2 1
p p p p
S T
+ = bar
N
,
1
.
Q= 0,06-A
2
-v
max
l/min
Q Q
p p
N
S
=
35
2
l/min

Calculation:
p bar
2
3
3
140 199 16 1780 35 199 16
199 1 16
131 =
- - + + - -
+
=
( , , ) [ , , , )]
, ( , )

p bar
1
2
3 5 140 131 1 6 26 = + - = , [( ) ,

Q= 0,06-19,9-12,7=15 l/min
Q
N
=
= 15
35
140 131
30
l/min


30.08.2011 28
Differential Cylinder Extending at an Inclined Plane with Negative Load

Layout:
F
T
= F
a
+F
E
+F
R
+[G-(-coso-sino)] daN

Given Parameters
F
T
= -6675 daN
P
S
= 210 bar
P
T
= 0 bar
A
1
= 53,5 cm
2

A
2
= 38,1 cm
2

= 1,4
v
max
= 25,4 cm/s
==> p
1
und p
2

) 1 (
)] ( [
3
2
2
2
2
1
+
+ +
=
A
A p F A p
p
T S
bar
2
1
2
p p
p p
S
T
+ = bar
N
,
1
.
Q= 0,06-A
1
-v
max
l/min
Q Q
p p
N
S
=
35
1
l/min

Calculation:
p bar
1
2
3
210 106 12 6675 0 106
1061 14
131 =
- + + -
+
=
( ) , [ ( )]
( , )

Caution!!!
Negative load is leading to cylinder cavitation.
Specified parameters to be changed by means of
using a larger cylinder size, increasing the system
pressure or reducing the necessary total force.
A
1
= 126 cm
2
A
2
= 106 cm
2
R=1,2
p bar
2 2
210 44
1 2
116 =

=
,

Q= 0,06-126-25,4=192 l/min
Q
N
=
= 192
35
210 44
88
l/min


30.08.2011 29
Differential Cylinder Retracting at an Inclined Plane with Negative Load

Layout:
F = F
a
+F
E
+F
R
+[G-(-coso-sino)] daN

Given Parameters
F = -6675 daN
P
S
= 210 bar
P
T
= 0 bar
A
1
= 53,5 cm
2

A
2
= 38,1 cm
2

= 1,4
v
max
= 25,4 cm/s
==> p
1
and p
2

) 1 (
)] ( ) (
3
2
2
3
2
2

+
+ +
=
A
A p F A p
p
T S
bar
] ) [(
2
2 1
p p p p
S T
+ = bar
N
,
2
.
Q= 0,06-A
2
-v
max
l/min
Q Q
p p
N
S
=
35
2
l/min

Calculation:
p bar
2
3
3
210 381 14 6675 0 381 14
3811 14
107 =
- - + + - -
+
=
( , , ) [ ( , , )]
, ( , )

p bar
1
2
0 210 107 14 202 = + - = [( ) , ]

Q= 0,06-38,1-25,4=58 l/min
Q
N
=
= 58
35
210 107
34
l/min


30.08.2011 30
Hydraulic Motor with a Positive Load

Layout:
T = o-J+T
L
[Nm]

Given Parameters
T = 56,5 Nm
P
S
= 210 bar
P
T
= 0 bar
D
M
= 82 cm
3
/rad
e
M
= 10 rad/s

==> p
1
and p
2

p
p p T
D
S T
M
1
2
10
=
+
+
t
bar
p p p p
S T 2 1
= + bar
N
,
1
.
Q
M
= 0,01-e
M
-D
M
l/min
Q Q
p p
N M
S
=
35
1
l/min

Calculation:
p bar
1
210 0
2
10 56 5
82
127 =
+
+
- -
=
t ,

p bar
2
210 127 0 83 = + =

Q
M
= 0,01-10-82=8,2 l/min
Q
N
=
= 8 2
35
210 127
5 3 , ,
l/min


30.08.2011 31
Hydraulic Motor with a Negative Load

Layout:
T = o-J-T
L [Nm]
Given Parameters
T = -170 Nm
P
S
= 210 bar
P
T
= 0 bar
D
M
= 82 cm
3
/rad
e
M
= 10 rad/s

==> p
1
and p
2

p
p p T
D
S T
M
1
2
10
=
+
+
t
bar
p p p p
S T 2 1
= + bar
N
,
1
.
Q
M
= 0,01-e
M
-D
M
l/min
Q Q
p p
N M
S
=
35
1
l/min

Calculation:
p
1
210 0
2
10 170
82
40bar =
+
+
- -
=
t ( )

p
2
210 40 0 170bar = + =

Q
M
= 0,01-10-82=8,2 l/min
Q
N
=
= 8 2
35
210 40
3 6 , ,
l/min


30.08.2011 32
Identification of the Reduced Masses of Different Systems

The different components (cylinder / motors ) have to be dimensioned for the layout of the
necessary forces of a hydraulic system, so that the acceleration and the deceleration of a mass is
correct and targeted.
The mechanics of the system are defining the stroke of the cylinders and motors.
Speed- and force calculations have to be carried out.
Statements with view to acceleration and its effects on the system can be made by fixing the reduced
mass of a system.
The reduced mass (M) is a concentrated mass, exerting the same force and acceleration
components as the regular mass at the correct system.
The reduced moment of inertia (I
e
) has to be considered for rotational systems.
The reduced mass has to be fixed in a first step for considerations with stroke measuring systems or
for applications with deceleration of a mass!
Newtons second axiom is used for the specification of the acceleration forces.
F m a = - F= force [N]
m= mass [kg]

a= acceleration [m/s
2
]

The following equation is applied for rotational movements:
I = - '' I u I= torque [Nm]
= moment of inertia [kgm
2
]

'' u = angular acceleration [rad/s
2
]


30.08.2011 33
Linear Drives
Primary Applications (Energy Method)

The mass is a concentrated mass and the rod l is weightless. The cylinder axis is positioned
rectangular to the rod l.
Relation between cylinder and rod:
' = = u
v
r
v
l
c m
'' = = u
a
r
a
l
c m

Needed torque for acceleration of the mass:
I = '' = - IX F r u
= - '' m l X
2
u I m l = -
2

= - m l X
a
l
m 2
'' = u
a
l
m

= - m lXa
m

==> F
m l a
r
m i a
m
m
=
- -
= - - i
l
r
=
m-i can be considered as mass movement m.
F m i a m i
l a
r
m i a M a
m
c
c c
= - - = - -
-
= - - = -
2
mit
a
r
a
l
c m
=
F= cylinder force
M= reduced mass
a
c
= acceleration of the cylinder rod
General validity: M m i = -
2

The same result can be obtained by the aid of the energy method (kinetic energy of the mass m). The
dependence of the mass movement with the cylinder movement can be specified with the help of the
geometry of the system.
Energy of the mass:
KE I m l = - ' = - - '
1
2
1
2
2 2 2
u u (I=m-i
2
)


30.08.2011 34
= - -
|
\
|
.
|
1
2
2
2
m l
v
r
c
(v
c
=r- ' u )
= - -
1
2
2
2
2
m
l
r
v
c

=
1
2
2
M v
c
- M=m-i
2
and i=l/r


30.08.2011 35
Concentrated Mass with Linear Movements

v is the horizontal component of v. v is positioned rectangular to rod l.
Energy method:
KE I m l = - ' = - - '
1
2
1
2
2 2 2
u u
= - -
' |
\
|
.
|
1
2
2
2
m l
v
r
( ' u =v/r)
= - - '
1
2
2
2
2
m
l
r
v
=
1
2
2 2
m i v - - '
with v=v-coso

==> KE m i v = - - '
1
2
2 2

=
-
- = -
1
2
1
2
2
2
2 2
m i
v M v
(cos ) o

with M m
i
=
2
2
(cos ) o
==> M is position-depending
If: o= 0 then, o=1 and M=mi
2

o=90then, coso=0 and M=
o=30then, coso=0,7 and M
o
=0
If a cylinder is moving a mass, as shown in the preceding figure, and the movement is situated
between -30and +30, the acceleration- and deceleration forces have to be calculated in the center
of motion with a reduced mass, twice as large as the one in the neutral center.


30.08.2011 36
Distributed Mass at Linear Movements

When considering the same rod l with the mass m, you can here also calculate the reduced mass of
the rod.

KE I X m l = - ' = - - - '
1
2
1
2
1
3
2 2 2
u u
1
3
2
- - m l
= - - -
' |
\
|
.
|
1
2
1
3
2
2
X m l
v
r
( ' u =v/r)
= - - - '
1
2
1
3
2
2
2
X m
l
r
v
=
1
2
1
3
2 2
X m i v - - - '
with v=v-coso
= - -
-
- = - -
1
2
1
3
1
3
2
2
2 2
X
m i
a
v M v
(cos )

M
m i
a
= -
- 1
2
2
2
(cos )


30.08.2011 37
Rotation

If considering now a rotating mass with a moment of inertia I, driven by a motor (ratio D/d).
KE I I
d
D
m = - ' = - ' -
1
2
1
2
2 2
u u ( ) I= moment of inertia [kgm
2
]
= -
|
\
|
.
| - '
1
2
2
2
I
d
D
u ' u = angular acceleration [rad/s
2
]
= - - '
1
2
2 2
I i u
=
1
2
2
I
e
- ' u I
e
= I-i
2

i=d/D

If a gearbox has to be used, i has to be considered.
If i=D/d, then I
e
=I/i
2


30.08.2011 38
Combination of Linear and Rotational Movement

A mass m is here moved by a wheel with radius r. The wheel is weightless.

KE m v = -
1
2
2

( ) = - - '
1
2
2
m r u v=r- ' u
= - - '
1
2
2 2
m r u
=
1
2
2
I
e
- ' u I
e
= m-r
2


30.08.2011 39
Hydraulic Resistances

The resistance of an area reduction is the change of the applied pressure difference Apto the
corresponding volume flow change.

dQ
p d
R
) (A
=

Orifice Equation

t
o
p d
Q
B
K Blende
A -
-
-
- - =
2
4
6 , 0
2

o
K
= flow coefficient (0,6-0,8)
= 0,88 [kg/dm
3
]
d
B
= orifice diameter [mm]
A p = pressure difference [bar]
Q
orifice
= [l/min]
Throttle Equation
Q
r
l
p p
Drossel
=
-
- -
-
t
q
4
1 2
8
( )
q=-v
Q
throttle
= [m
3
/s]
q = dynamic viscosity [kg/ms]
l = throttle length [m]
r = radius [m]
v = kinematic viscosity [m
2
/s]
= 880 [kg/m
3
]


30.08.2011 40
Hydro Accumulator

AV V
p
p
p
p
=
|
\
|
.
|
-
|
\
|
.
|
(
(
(
0
0
1
1
1
2
1
1
k k

k
k
(
(
(
(
(
(
|
|
.
|
\
|
A
=
1
1
0
0
1
2
1
p
p
V
V
p
p
V
V
p
p
p
p
0
0
1
1
1
2
1
1
=
|
\
|
.
| -
|
\
|
.
|
(
(
(
A
k k

k = 1,4 (adiabatic compression)
AV = effective volume [l]
V
0
= accumulator size [l]
p
0
= gas filling pressure [bar]
p
1
= service pressure min [bar] (pressure loss at the
valve)
p
2
= service pressure max [bar]

p
0
= <0,9*P
1

Provide an accumulator in the pressure circuit for
pressure-controlled pumps!
Swivel time of pump t
SA
of the pump catalog.
SA
t Q V - = A


30.08.2011 41
Heat Exchanger (Oil - Water)

ETD t t
l K
=
p
P
ETD
V
01
=
At
P
V
K
V
K
=
- 14

Calculation of At
l
is different, depending on the
respective hydraulic fluid.
V
l
= oil flow [l/min]
P
V
= dissipation power [kW]
t
l
= inlet temperature oil [C]
At
l
= cooling of the oil [K]
t
K
= inlet temperature cooling water [C]
At
K
= heating of the cooling water [K]
V
K
= cooling water flow [l/min]
ETD = inlet temperature difference [K]
p
01
= spec. cooling capacity [kW/h]

HFA HLP/HFD HFC
At
P
V
l
V
l
=
- 14 7 ,
At
P
V
l
V
l
=
- 36
At
P
V
l
V
l
=
- 17 2 ,

The size of the heat exchangers can be defined by the calculated value p
01
of the diagrams of the
different manufacturers.


30.08.2011 42
Example AB-Standards:


30.08.2011 43
Layout of a Valve

The necessary volume flow can be calculated
based on the cylinder data as well as on the
extending and retracting speeds.

P= P
S
system pr.-P
L
load pr.-P
T
return pressure
(Load pressure ~
3
2
*System pressure)
At optimal efficiency

F
T
= load force [daN]
P
S
= system pressure [bar]
P
T
= return pressure [bar]
A
1
= piston surface cm2
A
2
= ring surface cm2
= aspect ratio cylinder
v
max
= extending speed of the cylinder cm/s

p
1
and p
2

) 1 (
)] ( ) (
3
2
2
3
2
2

+
+ +
=
A
A p F A p
p
T T S
bar
] ) [(
2
2 1
p p p p
S T
+ = bar

N
,
1
.

Q= 0,06-A
2
-v
max
l/min
2
p p
X
Q Q
S
N
= l/min

X= 35 (Servo valve) pressure loss via a leading edge
X= 35 (Prop valve) pressure loss via a leading edge
(Prop valve with shell)
X= 5 (Prop valve) pressure loss via a leading edge
(Prop valve without shell)

Selection of a valve 10% larger than the
calculated nominal volume flow

Translation: Harm/March 16, 2011

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