Laboratory MET 230L-8

CYLINDER CIRCUITS

Objectives

To understand common cylinder specifications.

To study normal and regenerative cylinder circuit designs.

To determine experimentally how cylinder circuit design effects cylinder velocities.

Discussion
Cylinders
Hydraulic cylinders are available in many common styles and sizes. Cylinders for unique
applications can be special ordered in almost any size. Figure 8-1 is a sketch of a single ended
hydraulic cylinder. Several characteristics are used to specify cylinders. However, the three most
common characteristics used to specify a cylinder are its bore, rod diameter and stroke length.
Typically these characteristics are typed or stamped on the cylinder in the format of Bore X Rod
diameter X Stroke. For example, (3 X 5/8 X 12) would correspond to a cylinder with a three
inch bore, 5/8 diameter rod, and a one foot stroke length.

Figure 8-1 Single ended cylinder

The velocity of a piston is a function of flow and cylinder areas. Three areas characterize a
cylinder. These are the cap area, annulus area, and rod area. The cap area, Ac, is defined as the area
of the head end of the cylinder. The head end of the cylinder is that end which has no mechanical
penetration. The rod area, Ar, is simply the area of the piston rod. The annulus area, Aa, is
equivalent to the difference of the cap and rod areas.

305313539 Rev. 2/22/16

Page 1 of 25

Cylinder Circuits
Normal Cylinder Operation
Figure 8.2 is a general schematic of a system, which is plumbed to accomplish normal cylinder
operation. Under normal operation, cylinder extend and retract velocities are strictly functions of
pump flow and cylinder areas.

Figure 8.2 Normal cylinder circuit

Figure 8.3 shows how the pump flow, Qp, acts on the cap area, Ac, to produce the extend motion of
the cylinder. The return flow, Qr, is simply returned to the systems reservoir. In normal retract
motion the flows are simply reversed, that is the pump flow enters the annulus end of the cylinder
and the return flow exits the cap end of the cylinder. Equations (1) and (2) are used to calculate
extend and retract velocities for normal operation.

Figure 8.3 Cylinder in normal extend motion

Cylinder extend velocity:

305313539 Rev. 2/22/16

Page 3 of 25

Vext

Qp
Ac

(1)

Where:
Vext
is the cylinder extend velocity
Qp
is the pump flow
Ac
is the cylinder cap area
Cylinder retract velocity:
Vret

Qp
Ac Ar

Qp
Aa

(2)

Where:
Vret
is the cylinder extend velocity
Ar
is the cylinder rod area
Aa
is the cylinder annulus area

Equations (3) and (4) are used to determine the forces that develop during the extend and retract
motions of a cylinder undergoing normal operation.
Extend force:
Fext P Ac

(3)

Where:
Fext
is the cylinder extend force
P
is the system pressure
Retract force:
Fret P Ac Ar P Aa

Where:
Fret
is the cylinder retract force

Regenerative Cylinder Operation

305313539 Rev. 2/22/16

Page 5 of 25

(3)

Figure 8.4 is a general schematic of a system, which is plumbed to accomplish regenerative cylinder
operation. Under regenerative operation, cylinder extend velocity is a function of pump flow,
cylinder exhaust flow, and cylinder areas. A cylinders piston velocity is proportional to input flow.
With a constant flow to a double acting, single end rod cylinder, piston retract velocity is greater
than piston extend velocity. This is a result of the different volume requirements.
A method of increasing rod extension velocity without increasing pump size will be studied and
observed in this exercise. Increasing piston extend velocity is accomplished by using cylinder
exhaust flow to supplement pump flow during the extend motion. This process is called
regeneration.

Figure 8.4 Regenerative cylinder circuit

Figure 8.5 shows how the return flow, Qr, is combined with the pump flow, Qp, and acts on the cap
area, Ac, to produce the extend motion of the cylinder. Note that in the regenerative extend motion
none of the working fluid is returned to the reservoir. Also, note that the entire pump flow
effectively acts solely on the rod area of the cylinder. In regenerative operation, piston retract
motion is accomplished in the same manner as in normal operation. That is, the pump flow enters
the annulus end of the cylinder and the return flow exits the cap end of the cylinder. Equations (5)
and (6) are used to calculate extend and retract velocities for normal operation.

Figure 8.5 Cylinder in regenerative extend motion

Cylinder extend velocity:

305313539 Rev. 2/22/16

Page 7 of 25

Vext

Q p Qr
Ac

Q p Vext Aa
Ac

Qp
Ac

Vext

Ac Ar
Ac

(5)
Qp
Vext

Qp
Ac

A Ar
Ar
1 c
Ac

Where:
Vext
is the cylinder extend velocity
Qp
is the pump flow
Qr
is the return (exhaust) flow
Cylinder retract velocity:
Vret

Qp
Ac Ar

Qp
Aa

(6)

Where:
Vret
is the cylinder extend velocity
Ar
is the cylinder rod area
Aa
is the cylinder annulus area
Equations (7) and (8) are used to determine the forces that develop during the extend and retract
motions of a cylinder undergoing regenerative operation. Note that in the extend mode the pressure
applied to the cap area is partially balanced by pressure applied by the fluid on the annulus side of
the cylinder. (Refer to Figure 8.5.) Thus, the extend force is generated by the system pressure
acting on an effective area equivalent to that of the cylinder rod area.
Extend force:
Fext P Ac P Aa P Ar

(7)

Where:
Fext
is the cylinder extend force
P
is the system pressure
Retract force:
Fret P Ac Ar P Aa

Where:
Fret
is the cylinder retract force

Procedure
Part 1 Normal Cylinder Operation

305313539 Rev. 2/22/16

Page 9 of 25

(8)

1. Identify the Bosch test stand that you use to run tests. Record the stand number in Table 8.1.
2. Complete the schematic given in Figure 8-6 by using Automation Studio.
3. Obtain all of the information outlined in Table 8.1 for the stand chosen in procedure 1.
4. Using the information in Table 8.1, compute the following (use metric units):

Cylinder cap, rod, and annulus areas (mm2).

Rated pump flow (L/min).
Expected cylinder extend and retract velocities based on rated pump flow (m/s).

Show all calculations in the calculation section or on an attached worksheet. Record the results
of all calculations in Table 8.2
5. Build the normal cylinder circuit as in Fig. 8.6. Use a lever-operated directional valve to control
the cylinder. Read the flow rate on the flow meter.
6. Using the information obtained in procedure 5, calculate the extend and retract velocities based
on actual pump flow. Record the results in Table 8.2.
7. Record the system pressure while the piston is in motion and after it has reached the end of its
stroke.
5. Calculate the force developed while the rod is in motion and when it has reached the end of its
stroke.
6. Repeat procedures 7 and 8 this time actuating the directional control valve such that the cylinder
retracts. Record all information in Table 8.2.
7. Extend the rod and record the time of travel. From this time, calculate the piston velocity.
8. Retract the rod and record the time of travel. From this time, calculate the piston velocity.
9. Extend the rod and record the flow as indicated on the flow meter during the extend motion.
From this flow reading, calculate the piston velocity. Note: Pay close attention to what flow the
meter is reading.
10. Retract the rod and record the flow as indicated on the flow meter during the retract motion.
From this flow reading, calculate the piston velocity. Note: Pay close attention to what flow the
meter is reading.

305313539 Rev. 2/22/16

Page 11 of 25

Part 2 Regenerative Cylinder Operation

1. Complete the schematic I Automation Studio given in Figure 8-7 to reflect the circuit you
constructed on the Bosch test stand.
2. Using the information in Table 8.3, compute cylinder cap, rod, and annulus areas. Show all
calculations in the calculation section or on an attached worksheet. Record the results of all
calculations in Table 8.4.
3. Calculate expected extend and retract velocities based on actual pump flow for both
regenerative and normal operating modes. Record the results in Table 8.4.
4. Actuate the directional control valve to cause the cylinder to extend. Record the system
pressure while the piston is in motion and after it has reached the end of its stroke.
5. Calculate the force developed while the rod is in motion and when it has reached the end of its
stroke.
6. Repeat procedures 4 and 5 this time actuating the directional control valve such that the cylinder
retracts. Record all information in Table 8.4.
7. Extend the rod and record the time of travel. From this time, calculate the piston velocity.
8. Retract the rod and record the time of travel. From this time, calculate the piston velocity.

305313539 Rev. 2/22/16

Page 13 of 25

Laboratory MET230L-8
Cylinder Circuits

Name: Smith, Tyler K

Sec. 003

Lab Partner
Test Stand # 4 yellow Date:10/15/2014

Data/Results

Figure 8.6 Normal cylinder circuit

Table 8.1 Normal cylinder circuit specifications
TEST STAND NUMBER 4 YELLOW
Table 8.2 Results for normal circuit operation
Electric Motor
Power

Pump
1.1

Speed

kW

Displacement:

cm3/rev

rpm

Rated flow:

4.5

L/min

870.2

psi

115

Volts

at

three

Phase

at

Directional Control Valve

Bosch Part No.

Cylinder

0S1WV0SP1V7002GD
0

305313539 Rev. 2/22/16

rpm

Dimensions

Page 15 of 25

25x18x400 mm

305313539 Rev. 2/22/16

Page 17 of 25

Figure 8.7 Regenerative cylinder circuit

Table 8.3 Regenerative cylinder circuit specifications
Electric Motor
Power

Pump
1.1

Speed

kW

Displacement:

cm3/rev

rpm

Rated flow:

4.5

L/min

870.2

psi

115

Volts

at

three

Phase

at

Directional Control Valve

Bosch Part No.

Cylinder

0S1WV0SP1V7002GD
0

305313539 Rev. 2/22/16

rpm

Dimensions

Page 19 of 25

25x18x400 mm

Table 8.4 Results for regenerative circuit operation

305313539 Rev. 2/22/16

Page 21 of 25

Calculations
Show below all pertinent calculations required of this exercise. Indicate what units are used in the
calculations.
Area Calculation
A= pi^2r,
A= 490.9mm^2
Force calculation
F = P/A, P=847psi A= 490.9mm^2= .760in^2
F= 847psi/.760in^2
F= 644.5lbs
Cylinder Velocity, V
V= L/T L=.4m
Time = Volume of Cylinder/ Flow Rate , F= 1.35GPM= 5110305.9mm^3 v= 196360mm^3
Time= 196360mm^3/5110305.9mm^3= 0.0384min= 2.3sec
V=.4/2.3sec= 0.174m/sec

Questions
Part 1
1. Compare the tabulated results in Table 8.1 and discuss:

Variations in the velocities calculated using the four different methods.

They seem to be pretty similar. The method of recording travel time showed the shortest results.
This could be to the cylinder seeming to finish the stroke from the outside but isnt
completely full and extended on the inside

Differences in the magnitude of extend and retract velocities.

The retract velocity is about twice as fast as the extend velocity. This is due to the areas the forces
are applied to in retract and extend. For extension the force is applied to the cap which has an area
of 490.9mm^2 thus giving a larger volume to fill than the retract cycle. On retract the area acted on
is the annulus which is 236.9mm^2 so it has to fill roughly half the volume which explains the
speed difference
2. Which velocity calculation method is most accurate? Why?
The flow based velocity calculation is the most accurate. The flow meter on the stands is
accurate and a change in volume based on time can be took from that. With the given cylinder
geometries it is easy to calculate the time travel by the cylinder.

305313539 Rev. 2/22/16

Page 23 of 25

Part 2
1. Compare the calculated piston extend velocity in normal mode with the calculated extend
velocity in regenerative mode. How much faster does the rod extend in regenerative mode?
What accounts for this velocity increase?
It makes it about 8% faster. The velocity increase can be accounted for by the additional flow
added to the system by the fluid exiting the cylinder instead of just exiting into the tank.
2. Which is faster - regenerative extend velocity or retract velocity?
Extend because the area the fluid acts on is smaller which means a smaller volume has to be filled
allowing the cylinder to retract faster.
3. Compare the extend force while in regenerative mode with the retract force. Discuss the
variation.
Extend force is around 600lbs while the retract is around 300lbs. this variation is due to how the
fluid Is ran in the regenerative system. On extend there is added pressure in the high pressure
line to the system from the fluid exiting the cylinder. On retract the fluid exiting the other side
of the cylinder just drains into the tank not adding extra pressure to the system.

305313539 Rev. 2/22/16

Page 25 of 25