PRINCIPLES

OF HYDRAULIC
SYSTEMS DESIGN

PRINCIPLES
OF HYDRAULIC
SYSTEMS DESIGN
SECOND EDITION
PETER CHAPPLE

MOMENTUM PRESS, LLC, NEW YORK

Principles of Hydraulic Systems Design, Second Edition

Copyright Momentum Press, LLC, 2015.
All rights reserved. No part of this publication may be reproduced, stored
in a retrieval system, or transmitted in any form or by any means
electronic, mechanical, photocopy, recording, or any otherexcept for
brief quotations, not to exceed 400 words, without the prior permission
of the publisher.
First published by Momentum Press, LLC
222 East 46th Street, New York, NY 10017
www.momentumpress.net
ISBN-13: 978-1-60650-452-9 (print)
ISBN-13: 978-1-60650-453-6 (e-book)
Momentum Press Fluid Mechanics Collection
DOI: 10.5643/9781606504536
Cover and interior design by Exeter Premedia Services Private Ltd.,
Chennai, India
10 9 8 7 6 5 4 3 2 1
Printed in the United States of America

Abstract
This is the second edition of the book which was published in 2002. Fluid
power systems are manufactured by many organizations for a very wide
range of applications, which often embody differing arrangements of components to fulfill a given task. Hydraulic components are manufactured to
provide the control functions required for the operation of a wide range of
systems and applications. This second edition of the book is structured so
as to give an understanding of:

The basic types of components, their operational principles and the

estimation of their performance in a variety of applications. Component manufacturer diagrams are included to aid the understanding of
the mechanical principles involved. This second edition has added a
description of the digital control methods for independently operated
valves for pumps and motors.
A resume of the flow processes that occur in hydraulic components.
A review of the modeling process for the efficiency of pumps and
motors. This second edition includes an analysis for estimating the
mechanical loss in a typical hydraulic motor.
The way in which circuits can be arranged using available components to provide a range of functional system outputs. This includes
the analysis and design of closed loop control systems and some
applications.
The analytical methods that are used in system design and the prediction of steady state and dynamic performance in a range of applications. This second edition deals more extensively with the analysis of
hydraulic circuits for different types of hydrostatic power transmission systems and their application.
This second edition also includes a description of the use of international standards in the design and management of hydraulic systems.

KEY WORDS
closed loop control systems, contamination control filters, digital displacement control of pumps and motors, flow and pressure control valves,
v

vi Abstract

flow loss, fluid bulk modulus, fluid compressibility, fluid pressure loss,
fluid viscosity, hydraulic circuits, hydraulic cylinders, hydraulic filters,
hydraulic pumps and motors, hydraulic seals, hydrostatic transmissions,
international standards, mechanical efficiency, mechanical power loss,
oil coolers, oil flow process, pressurized gas accumulators, proportional
valves, pump and motor displacement control, volumetric efficiency, volumetric power loss

Contents
List of Figures

ix

List of Tables

xvii

Acknowledgments

xix

Introduction to Second Edition

xxi

Chapter 1 Hydraulic Power Transmission and Its Control

Chapter 2 Hydrostatic Pumps and Motors

Chapter 3 Hydraulic Cylinders

29

Chapter 4 Pressure Control Valves

43

Chapter 5 Flow Control Valves

53

Chapter 6 Ancillary Equipment

61

Chapter 7 Circuit Design

75

Chapter 8 Flow Processes in Hydraulic Systems

113

Chapter 9 Operating Efficiencies of Pumps and Motors

129

Chapter 10 Control System Design

149

Chapter 11 Performance Analysis

199

Chapter 12 Systems Management

263

Appendix

273

References

277

Index

279

vii

List of Figures
Figure2.1. External gear pump and motor.

Figure2.2. Internal gear pump.

Figure2.3. Balanced vane pump. 

Figure2.4. Variable displacement vane pump.

10

Figure2.5. Axial piston variable displacement pump and motor.

11

Figure2.6. Diagram of a pump port plate.

11

Figure2.7. Bent axis type axial piston motor.

12

Figure2.8. Pump performance characteristics.

15

Figure2.9. Motor performance characteristics.

16

Figure2.10. Radial piston eccentric motor (a) valve housing

(b) complete motor assembly. 

19

Figure2.11. 
Cam-type hydraulic motor.

19

Figure2.12. Gerotor, or orbit-type low speed high torque motor. 

20

Figure2.13. Digital control valves for a radial piston motor.

21

Figure2.14. Typical maximum speeds for motors of various types. 25

Figure2.15. Typical mass values for a range of motor types.

26

Figure3.1. Typical double-acting actuator. 

30

Figure3.2. Actuator of tie rod construction. 

31

Figure3.3. Actuator mountings (a) with position transducer (b).

31

Figure3.4. Actuator mounting styles (a) Actuator flange mounted

to front or rear end cover with the rod end unguided (b)
Actuator trunnion mounted with the rod end guided (c)
Spherical coupling with the rod end guided (d) Actuator
flange mounted with the rod end guided.
32
Figure3.5. Section view of a typical cylinder showing the
various seals.
ix

33

x List of Figures

Figure3.6. Telescopic cylinder.

35

Figure3.7. Actuator cushioning.

36

Figure3.8. Velocity and pressure variation.

38

Figure3.9. Rack and pinion rotary actuator.

39

Figure3.10. Vane rotary actuator.

39

Figure4.1. Poppet and piston-type valves.

44

Figure4.2. Two-stage poppet type relief valve.

44

Figure4.3. Two-stage cartridge relief valve.

45

Figure4.4. Dual relief valves in actuator circuit.

46

Figure4.5. Reducing valve operating principles.

47

Figure4.6. Reducing valve.

47

Figure4.7. Cartridge type of counterbalance load control valve.

48

Figure4.8. Flow characteristics of the counterbalance valve

in Figure4.7.

48

Figure4.9. Extending actuator controlled by a counterbalance valve

with a pulling load.
49
Figure4.10. Operating pressures.

50

Figure5.1. Four-way directional control valve (DCV).

54

Figure5.2. Manually operated DCV. 

54

Figure5.3. Proportional control valve. 

55

Figure5.4. Adjustablerestrictor valve. 

56

Figure5.5. Pressure compensated valve.

57

Figure5.6. Pressure compensated flow control valve. 

57

Figure5.7. Central bypass valve. 

59

Figure5.8. Bypass valve connecting the pump flow to port A and

return to port B.

60

Figure6.1. Accumulators: (a) bladder type and (b) typical

piston type.

62

Figure6.2. Accumulator pressure.

63

Figure6.3. Variation in adiabatic index with pressure and

temperature for nitrogen.

64

Figure6.4. Important contamination aspects in vane and

gear pumps. 

65

Figure6.5. Wear particle generation in piston pumps.

66

Figure6.6. High-pressure filter. 

67

List of Figures xi

Figure6.7. Beta ratio for filters. 

68

Figure6.8. Downstream fluid quality and the beta ratio. 

69

Figure6.9. ISO 4406 standard code for contamination levels.

70

Figure6.10. Cooler performance characteristics.

73

Figure7.1. Flow and pressure variation.

76

Figure7.2. Two-position four-way valve.

77

Figure7.3. Two-position three-way valve.

77

Figure7.4. Closed center valves.

78

Figure7.5. Tandem center valves.

78

Figure7.6. Open center valves

78

Figure7.7. Open center valve connected to tank

79

Figure7.8. Pilot-operated check valve.

80

Figure7.9. Actuator circuit using a POCV.

80

Figure7.10. Meter-in control for actuator extension.

81

Figure7.11. Pressure and velocity variations with meter-in control. 82

Figure7.12. Meter-out control.

83

Figure7.13. Bleed-off control.

84

Figure7.14. Multiple actuator circuit with meter-in control.

84

Figure7.15. Four-way valve velocity control.

85

Figure7.16. Valve pressures during extension.

87

Figure7.17. Interaction between the flow and the force

characteristics during extension.

87

Figure7.18. Actuator retracting.

89

Figure7.19. Nonsymmetrical valve metering.

92

Figure7.20. Load locus of velocity ratio against force ratio.

92

Figure7.21. Central bypass valves in series.

93

Figure7.22. Bypass valve characteristics.

93

Figure7.23. Central bypass valve with notched metering edges

in three positions.

94

Figure7.24. Pressure-compensated bypass valve with load sensing. 95

Figure7.25. Variable displacement pump pressure limiting and load
sensing control.
97
Figure7.26. Constant power control. 

97

Figure7.27. Pump operating characteristics.

98

xii List of Figures

Figure7.28. Accumulator charging circuit. 

99

Figure7.29. Rotary hydrostatic transmission circuit.

100

Figure7.30. Motor brake circuit.

101

Figure7.31. Linear actuator hydrostatic transmission circuit.

102

Figure 7.32. Secondary control system.

103

Figure7.33. Radial piston motor with digitally operated valves

(as in Figure2.12).

103

Figure7.34. Poppet valve for cylinders.

104

Figure7.35. Pilot circuit for active control of the motor

cylinder valves.

105

Figure7.36. Wind turbine hydrostatic power transmission system.  106

Figure7.37. Load control circuit using counterbalance valves.

107

Figure7.38. Double pump system with unloading valve.

108

Figure7.39. Sequence valve used for operation in a press circuit. 108

Figure7.40. High pressure filter circuits.

109

Figure 7.41. High and low pressure filter circuits.

110

Figure8.1. Oil viscosity variation with pressure and temperature. 114

Figure8.2. Moody chart for determining the friction factor.

116

Figure8.3. Flow between parallel plates.

117

Figure8.4. Sharp-edged orifice.

118

Figure8.5. Flow coefficient variation with Reynolds number.

120

Figure8.6a. Single-stage poppet-type relief valve.

121

Figure8.6b. The valve in open position.

121

Figure8.7. Valve pressure flow characteristic from Equation 8.11. 123

Figure8.8. Spool valve.

124

Figure8A.1 Flow through a pipe.

125

Figure9.1. Variation in overall efficiency.

134

Figure9.2. Radial piston eccentric-type motor.

137

Figure9.3. Slipper hydrostatic bearing.

138

Figure9.4. The effect of outer bearing friction on the slipper.

140

Figure9.5. Cross-sectional view of the hydrostatic slipper.

141

Figure10.1. Valve actuator circuit.

150

Figure10.2. Valve characteristics.

151

Figure10.3. Open-loop time response.

152

List of Figures xiii

Figure10.4. System block diagram.

153

Figure10.5. Simplified block diagram.

153

Figure10.6. Step response.

154

Figure10.7. Fluid compressibility.

155

Figure10.8. The effect of load pressure on the valve characteristics.157

Figure10.9. Valve flow coefficients.

159

Figure10.10. Sinusoidal flow variations and actuator displacement. 163

Figure 10.11. Bode plot for valve actuator open-loop transfer
function.165
Figure10.12. Electrohydraulic position control system block
diagram.167
Figure10.13. Valve actuator block diagram.

168

Figure10.14. Valve underlap.

169

Figure10.15. Valve pressure gain.

170

Figure10.16. Block diagram of steady state conditions.

171

Figure10.17. Valve hysteresis.

172

Figure10.18. Pressure control.

174

Figure10.19. Frequency response for integral plus proportional

control.176
Figure10.20. Frequency response for proportional plus derivative
control.178
Figure10.21. Phase advance frequency response.

179

Figure10.22. Pressure feedback control (fE = 0).

181

Figure10.23. Hydrostatic system block diagram.

184

Figure10.24. Steady state torque diagram of the load and

motor control.

187

Figure10.25. Block diagram for secondary control system.

187

Figure10.26. The relationship between turbine torque and speed

at a given wind speed.

191

Figure10.27. Relationship between motor displacement and

turbine speed and closed-loop control for a fixed
speed of the motor [9, 10].

193

Figure10.28. Turbine speed control system block diagram.

193

Figure10.29. Actuator control using a variable displacement pump. 195

Figure11.1. Single-ended actuator.

202

xiv List of Figures

Figure11.2. Winch driven by motor and reduction gearbox.

204

Figure11.3. Hydraulic winch with gearbox.

205

Figure11.4. Gantry crane.

209

Figure11.5. Circuit diagram.

214

Figure11.6. Fluid resistance in fittings.

216

Figure11.7. Weight loaded system.

220

Figure11.8. Valve dimensions.

221

Figure11.9. Equivalent circuit for actuator extension.

221

Figure11.10. Valve performance characteristics.

226

Figure11.11. Open-loop frequency response.

230

Figure11.12. Injection-moulding machine schematic diagram.

231

Figure11.13. Basic injection-moulding machine circuit.

233

Figure11.14. Variation of actuator pressure and displacement.

234

Figure11.15. Hydraulic circuit.

236

Figure11.16. Cooler performance characteristics.

236

Figure11.17. Oil inlet temperature.

239

Figure11.18. Pump control strategy.

243

Figure11.19. Variable displacement pump with pressure

compensation and flow control.

243

Figure11.20. Pump power (torque) control.

244

Figure11.21. Hydraulic potentiometer.

246

Figure11.22. Vehicle crusher unloading pump circuit.

247

Figure11.23. Bending machine schematic.

248

Figure11.24. Bending machine circuit.

248

Figure11.25. Alternative load sensing system.

249

Figure11.26. Hydraulically operated crane.

250

Figure11.27. The effect of changes in external forces on steady

state errors.

250

Figure11.28. The effect of adding proportional plus integral

compensation.251
Figure11.29. Step response with the P + I compensator.

252

Figure11.30. Dynamic responses using a PID compensator.

253

Figure11.31. The application of load pressure feedback.

254

List of Figures xv

Figure11.32. Turbine torque variation with turbine speed at

different wind speeds and turbine blade pitch angle .260
Figure11.33. Nonlinear simulation of turbine speed to change
of wind speed at50 s.

260

Figure12.1. The complete partnership.

266

Figure12.2. The bathtub life curve.

267

Figure12.3. Valve actuator system.

268

List of Tables
Table 2.1. Comparison of pump types

17

Table 2.2. Motor data

25

Table 3.1. Maximum piston rod extension (refer to Figure3.4)

33

Table 3.2. Summary of typical rotary actuator performance

40

Table11.1. Restrictor valve characteristics

201

Table11.2. Motor data

206

Table11.3. Cable information

210

Table11.4. Motor performance

212

Table11.5. Pipe pressure loss

213

Table11.6. Valve flow characteristics

218

Table11.7. Valve data

224

Table11.8. Valve flow/pressure characteristic, x = 4 mm

225

Table11.9. Valve flow/pressure characteristic, x = 5 mm

226

Table11.10. Power dissipated in the cooler

238

Table11.11. Dynamic performance parameters

256

Table11.12. Dynamic performance parameters

257

Table11.13. Hydrostatic transmission parameters

258

xvii

Acknowledgments
The author would like to give particular thanks to Steve Skinner [1] who
provided information and enthusiastic support from his wide range of
experience in the hydraulics field and who has recently published a book
on the history of fluid power. Also, thanks to John Sidders who had used
the first edition for leading a course and was able to provide useful comments on various aspects of the second edition and to Nick Peppiatt who
made a valuable contribution on cylinder seals.
The author gratefully acknowledges the assistance given by Steven
Brown and Steve Clarke who provided sectional drawings of motors.
Thanks are also due to Trevor Hornsby, Mike Day, Graham Miller, and
John Taylor for their assistance in the final stages of completing this
second edition of the book.
The author wishes to acknowledge the manufacturers who provided
component diagrams and illustrations for the book.

Diinef
Danfoss
Bosch Rexroth
Kawasaki Precision Machinery
Sun Hydraulics
Pall
Parker
Eaton
Mactaggart, Scott
Hallite

xix

Introduction to Second
Edition
The first edition of this book was intended to provide knowledge of
hydraulic components, their operating characteristics and available circuit
arrangements to assist in the design of hydraulic systems for a range of
applications. For some circuits it is important to predict the dynamic performance of the overall system particularly where closed loop control is
being employed. For this purpose and to provide a general understanding
of how parameters vary transiently analytical methods are developed that
provide techniques for studying the dynamics of systems. In this second
edition these features have been retained and expanded upon so as to evaluate the performance of some hydrostatic transmission examples.
In the period since the first edition there has been a considerable
expansion in the use of digital computers for control purposes which has
been accompanied by developments in the instrumentation field and use
of electromechanical valves. This technology often involves closed loop
control methods for example, the control of motor speed in a hydrostatic
transmission. This raises issues of dynamic performance and stability,
areas that are expanded in this second edition.
It is useful to have an understanding of the mechanical losses in
pumps and motors and a section has been added to model frictional processes in a typical hydrostatic motor which shows the effects of friction on
torque and mechanical efficiency.
Independently operated valves for pumps and motors are not a new
technological development but their use is becoming more apparent
because of the options that are available for displacement control. The
advantages of this technology are that conventional distributor valves and
displacement change mechanisms are avoided which eliminates their frictional and volumetric losses and consequently results in increased effi-

xxi

xxiiIntroduction to Second Edition

ciency particularly at reduced displacement. The design aspects of servo

systems to provide this important feature are discussed.
There has been a considerable development of industrial standards
particularly in the fields of the determination of dangerous failure possibilities and system safety. These standards are referred to where applicable
and discussed in the final chapter on systems management. Relevant standards are listed in the Appendix.

CHAPTER 1

Hydraulic Power
Transmission and Its
Control

1.1INTRODUCTION
Hydraulic fluid power is one of the oldest forms of power transmission
which, despite the period of rapid growth of electric power generation,
became accepted for driving a wide range of machines because of the inherent advantages that it has over other available forms of power transmission.
The increased reliability and life that resulted from the introduction
of oil-based fluids and nitrile rubber sealing elements created a rapid
growth in the use of fluid power transmission systems for a large variety
of machine applications. Some of the advantages that hydraulic power has
over other transmission mediums are summarized:
The equipment designer is released from the dimensional limitations that are imposed by conventional gears and drive shafts.
Stepless speed control can be obtained with relatively little increase
in circuit complexity.
The high ratio of power to mass allows fast response and a low
installed weight at the point of application.
The available output force is independent of operating speed.
Stalled loads can be maintained for indefinite periods.
The introduction of electronic control into fluid power has created scope
for its use in a wide range of machine applications particularly when operation by computers or programmable logic controllers (PLCs) is required.

2 PRINCIPLES OF HYDRAULIC SYSTEMS DESIGN

Electronic devices have improved the accuracy of control using closed

loop control techniques in many applications that have traditionally been
served by hydromechanical open loop systems.
Whether or not fluid power transmission is adopted in a particular
application depends on a number of features that would require consideration for a comparative study to be made if different types of power
transmission are to be evaluated.

1.2FLUID POWER SYSTEM DESIGN

There are broad categories of the types of fluid power systems in normal
use for which there is a range of available components for any chosen
system. The type of circuit employed often depends on company practice
or user choice and, as a consequence, this often has an important influence
on the components selected for the system. However, there are technical
aspects that can be used to evaluate the performance of systems, which
the designer needs to be aware of in order to provide some influence in the
process of selecting both the type of circuit to be used and the components.
1.2.1 COMPONENT SELECTION
Circuits can be arranged in various ways using alternative components to
provide a system for any given application. Additionally, different component designs are available to perform a specific function and because of
this and their influence on circuit design, the component selection process
does not easily lend itself to a discrete synthesized approach, as it requires
knowledge of the:
Range of hydraulic components that are available.
Operating characteristics of the components and their use in circuits and control systems.
Available types of hydraulic circuits.
Analytical methods for determining the system performance to
meet the machine specification.
1.2.2 CIRCUIT SELECTION
Generally speaking, the type of circuit that is chosen for a given application depends on a number of factors that include:

Hydraulic Power Transmission and Its Control3

First cost
Weight
Ease of maintenance
Operating cost
Machine duty cycle

1.2.3 SYSTEM DESIGN PROCESS

The major activities involved in the design process can be summarized as
follows:
Evaluate the machine specification and determine the type of
hydraulic system to be used.
Establish the types and sizes of the major hydraulic components.
Select an appropriate design of the hydraulic circuit.
Carry out a performance analysis of the system and determine its
ability to meet the machine specification.
This process, or parts of it, may need to be repeated as the final design is
evolved.

1.3CONTENTS OF THE COURSE BOOK

Bearing in mind the foregoing comments, this book has been arranged to
provide background knowledge for the design of fluid power systems. The
contents include:
Descriptions of major hydraulic components and circuits and their
performance characteristics.
Methods for analyzing the flow in pipes and components and flow
forces on valves.
The modeling of the efficiency of pumps and motors.
Techniques for the design and analysis of control systems.
Methods for the analysis of system performance.
This book is, therefore, aimed at providing the required background
knowledge in the design of hydraulic fluid power systems and their application in a wide range of engineering equipment and machines.

Index
A
Accumulators
adiabatic index variation,
6465
pressure, 6263
types, 6162
Ancillary equipment
accumulators
adiabatic index variation,
6465
pressure, 6263
types, 6162
contamination control
circuit design, 109110
components, 6566
filters, 6770
coolers
characteristics, 73
thermodynamic aspects, 72
types, 7172
reservoirs, 73
Axial piston motor
bent axis type, 1112
variable displacement pump
type, 1011
B
Bending machines, 247249
Beta ratio, 6668
BFPA. See British Fluid Power
Association (BFPA)

Bleed-off control, 8384

British Fluid Power Association
(BFPA), 68, 273275
British standards (BS), 273275
BS. See British standards (BS)
Bulk modulus, 154
C
Central bypass valve
actuator force, 224
flow analysis, 221223
valve characteristics, 223224
valve dimensions, 220, 221
valve operation, 225226
weight loaded system, 220
Central bypass valves, 5860
Circuit design
contamination control,
109110
directional control
three-position valves,
7879
two-position valves, 7677
hydrostatic transmissions
(see Hydrostatic
transmissions)
load holding valves, 7980
pilot operated valve circuits,
106108
pressure and flow, 7576
types, 75

280Index

variable displacement pump

control
accumulator charging,
9899
load-sensing, 96, 97
power control, 9698
velocity control
bleed-off control, 8384
four-way valve restrictive
control (see
Four-way valve
restrictive
control)
meter-in control, 8082
meter-out control, 8283
Compensation techniques
integral plus proportional
compensation,
176177
performance analysis
load pressure feedback,
253254
outcomes, 254
PID compensation,
252253
proportional plus integral
compensation,
251252
steady state accuracy,
249250
phase advance, 177179
PID control, 179180
pressure feedback, 180181
proportional plus derivative
control, 177, 178
Contamination control
circuit design, 109110
components, 6566
filters
beta ratio, 6768
downstream fluid quality,
6869
high-pressure, 6667
ISO 4406 standard code,
68, 70

Control system design

closed-loop position, stability
block diagram, 167168
stability criterion, 166
system design, 166167
valve leakage and
hysteresis,
168172
closed-loop system
performance
position control, 172173
pressure control, 174175
velocity control, 173174
compensation techniques
integral plus proportional
compensation,
176177
phase advance, 177179
PID control, 179180
pressure feedback,
180181
proportional plus
derivative
control, 177, 178
fluid compressibility
bulk modulus, 154
hydraulic stiffness,
155156
frequency response
simple actuator, 163164
valve actuator system,
164166
hydrostatic systems (see
Hydrostatic systems)
pump-controlled systems,
195196
simple valve actuator (see
Simple valve actuator
control)
system frequency response
tests, 194195
valve actuator dynamic
response
actuator flows, 159160
actuator force, 160161

Index 281

actuator position, 161162

pressure shock control
in open-loop
systems,
162163
valve flow, 156159
valve selection, 162

Coolers
characteristics, 73
thermodynamic aspects, 72
types, 7172
Coulomb friction torque, 132133
Counterbalance valves
cartridge type, 4748
extending actuator controlled,
49
flow characteristics, 4849
operating pressures, 5051

D
DCV. See Directional control valve
(DCV)
Digital valves
benefits, 2223
high pressure supply, 2021
low pressure supply, 21
Directional control
three-position valves, 7879
two-position valves, 7677
Directional control valve (DCV),
5355
Double-acting actuator, 2930
Dual relief valves, 46
E
EHSRs. See Essential Health and
Safety Requirements
(EHSRs)
EN. See European standards (EN)
Essential Health and Safety
Requirements (EHSRs),
269
European standards (EN), 273275

F
Failure modes effects analysis
(FMEA), 266268
Fault analysis
FMEA, 268269
FTA, 267268
methods, 266
parameters, 270271
Fault tree analysis (FTA), 266268
Filters
beta ratio, 6768
downstream fluid quality,
6869
high-pressure, 6667
ISO 4406 standard code, 68, 70
Fixed displacement units
external gear pumps and
motors, 78
internal gear pumps, 8
vane pumps and motors, 89
Flow control valves
central bypass, 5860
DCV, 5355
pressure compensated, 5658
restrictor, 5556
types, 53
Flow processes. See Hydraulic
systems, flow processes
Fluid compressibility
bulk modulus, 154
hydraulic stiffness, 155156
Fluid power system, 23
FMEA. See Failure modes effects
analysis (FMEA)
Four-way valve restrictive control
actuator extending
actuator force, 8688
valve flow characteristics,
8587
actuator retracting, 8890
bypass control with fixed
displacement pumps
closed center valves,
9596

282Index

open center valves, 9394

circuit diagram, 8485
valve sizing, 9091
valves with nonsymmetrical
metering, 9192
FTA. See Fault tree analysis (FTA)
G
Gantry crane
cable information, 210
installation details, 208209
low speed motor, 210
motor flow, 211
pipe sizes, 213, 214
wheel drive, 211212
H
High-pressure filter, 6667
circuits, 109110
Hydraulic cylinders
actuator selection
actuator force, 3536
cushioning, 3638
rotary actuators, 3940
double-acting actuator, 2930
end covers, 30, 31
mounting methods
actuator mounting styles,
32
Euler failure criteria,
3132
flange and trunnion
mounting, 3031
maximum piston rod
extension, 3233
position transducers and
proximity switches, 34
seals, 3234
telescopic cylinders, 3435
Hydraulic power
advantages, 1
fluid power system design, 23
Hydraulic stiffness, 155156

Hydraulic systems, flow processes

annular space, 144146
fluid properties, 113114
laminar flow, 117118
orifice flow, 118120
pipes
flow and pressure loss
relationship,
125127
Moody chart, 115117
pressure loss, 114115
tilted slipper, 146147
valve force analysis
change in momentum,
119120
poppet valves (see Poppet
valves)
spool valves, 123124
Hydraulic systems management
aspects, 264265
cleanliness, 265267
fault analysis
FMEA, 268269
FTA, 267268
methods, 266
parameters, 270271
objectives, 265
standards, 269270 (see also
British Fluid Power
Association (BFPA))
Hydrostatic pumps and motors
digital valves
benefits, 2223
high pressure supply,
2021
low pressure supply, 21
equations
flow and speed
relationship, 13
pump selection parameters,
16, 17
torque and pressure
relationship,
1416

Index 283

fixed displacement units

external gear pumps and
motors, 78
internal gear pumps, 8
vane pumps and motors,
89
general considerations, 2324
influencing factors, 5
low speed motors
applications, 1718
radial piston motors,
1820
performance characteristics
comparison
displacements and
maximum
speeds, 2425
typical mass values, 2627
selection factors, 6
variable displacement unit
axial piston, 1011
bent axis type axial piston
motor, 1112
pump port plate, 1011
vane pumps, 910
Hydrostatic systems
motor control systems
closed loop, 187188
displacement controller,
186187
torque, 186
pump-controlled
flow, 182183
torque, 183185
wind turbine
benefits and limitations,
189190
speed control, 192193
torque and speed
relationship,
190192
Hydrostatic transmission
primary control system,
254256

secondary control system,

256258
wind turbine (see Wind
turbine)
Hydrostatic transmissions
digital operation, 102105
linear actuator transmissions,
101102
motor brake circuit, 101
motor controlled systems, 102,
103
pump controlled systems,
100101
wind turbines, 105106
I
Injection-moulding machine
accumulator, 232233
actuator, 231232
circuit, 233234
motor, 232
pressure shocks, prevention,
234235
system data, 231
International standards (ISO),
273275
ISO. See International standards
(ISO)
L
Linear actuator transmissions,
101102
Load holding valves, 7980
Low speed motors
applications, 1718
radial piston motors, 1820
M
Mechanical loss modeling
generalised model assumptions,
135136
hydrostatic bearing, 138139

284Index

hydrostatic bearing leakage

flow, 140141
mechanical efficiency, 143
outer bearing friction, 139140
radial piston motor analysis,
136138
sliding contacts friction, 139
slipper and eccentric interface,
141142
viscous and coulomb friction
torque, 132133
Meter-in control, 8082, 199201
Meter-out control, 8283
Motor brake circuit, 101
Motor controlled systems, 102,
103
Motor control systems
closed loop, 187188
displacement controller,
186187
torque, 186
Motors and pumps. See
Hydrostatic pumps and
motors
O
Oil cooling
duty cycle, 236
heat generated, 237239
heat loss, 239
pump efficiency, 240
system data, 235236
P
Performance analysis
central bypass valve
actuator force, 224
flow analysis, 221223
valve characteristics,
223224
valve dimensions, 220,
221
valve operation, 225226

weight loaded system, 220

compensation techniques
load pressure feedback,
253254
outcomes, 254
PID compensation,
252253
proportional plus integral
compensation,
251252
steady state accuracy,
249250
control system design, 228230
gantry crane (see Gantry crane)
hydrostatic transmission
primary control system,
254256
secondary control system,
256258
wind turbine (see Wind
turbine)
injection-moulding machine
(see Injectionmoulding machine)
meter-in control, 199201
oil cooling (see Oil cooling)
pressure losses
at 20C, 215216
at 60C, 216217
components, 214215
pump requirements, 217
pump and motor efficiencies,
226228
pump control applications
bending machines,
247249
vehicle crusher unloading
pump circuit,
246247
simple actuator cushion,
218220
single-ended actuator valve
control
actuator extension, 203

Index 285

actuator retraction,
202203
data, 201202
single stage relief valve,
217218
vehicle transmission (see
Vehicle transmission)
winch application (see Winch
application)
PID. See Proportional, integral,
and derivative (PID)
compensation
Pilot-operated check valve
(POCV), 7980
Pilot operated valve circuits,
106108
POCV. See Pilot-operated check
valve (POCV)
Poppet and piston-type valves, 43
Poppet valves
flow, 122
momentum force, 120122
pressure flow characteristics,
122123
Pressure compensated valves,
5658
Pressure control valves
counterbalance
cartridge type, 4748
extending actuator
controlled, 49
flow characteristics, 4849
operating pressures, 5051
pressure reducing valves,
4647
relief valves
single-stage, 4345
two-stage, 4446
types, 43
Proportional control valves, 5455
Proportional, integral, and
derivative (PID)
compensation, 179180
Proportional plus integral
plus derivative (PID)

compensation, 252253
Pump control applications
bending machines, 247249
vehicle crusher unloading
pump circuit, 246247
Pump controlled systems,
100101
Pump-controlled systems,
195196
hydrostatic systems
flow, 182183
torque, 183185
Pump port plate, 1011
Pumps and motors. See
Hydrostatic pumps and
motors
Pumps and motors, operating
efficiencies
loss analysis
theoretical performance,
130131
volumetric flow loss,
131132
mechanical and volumetric
efficiency, 129130
mechanical loss modeling
generalised model
assumptions,
135136
hydrostatic bearing,
138139
hydrostatic bearing
leakage flow,
140141
mechanical efficiency, 143
outer bearing friction,
139140
radial piston motor
analysis,
136138
sliding contacts friction,
139
slipper and eccentric
interface,
141142

286Index

viscous and coulomb

friction torque,
132133
outcomes, 143144
unit efficiency, 133135
R
Rack and pinion rotary actuator,
3940
Radial piston motor analysis,
136138
Radial piston motors, 1820
Relief valves
single-stage, 4345
two-stage, 4446
Reservoirs, 73
Restrictor valves, 5556
Rotary actuators, 3940
Rotary hydrostatic transmission
circuit, 100101
S
Simple actuator cushion, 218220
Simple valve actuator control
closed-loop system, 152154
open-loop system
circuit and force
characteristics,
149150
time response, 151152
valve characteristics,
150151
system response, 154
Single-ended actuator valve
control
actuator extension, 203
actuator retraction, 202203
data, 201202
Single-stage relief valve, 4345
Single stage relief valve, 217218
T
Telescopic cylinders, 3435

Three-position valves, 7879

Two-position valves, 7677
Two-stage relief valves, 4446
V
Valve force analysis
change in momentum, 119120
poppet valves (see Poppet
valves)
spool valves, 123124
Valves
central bypass valves, 5860
circuit design
load holding valves, 7980
three-position valves,
7879
two-position valves, 7677
digital valves
benefits, 2223
high pressure supply,
2021
low pressure supply, 21
dual relief valves, 46
flow control valves
central bypass, 5860
DCV, 5355
pressure compensated,
5658
restrictor, 5556
types, 53
four-way valve restrictive
control
closed center valves,
9596
open center valves, 9394
load holding valves, 7980
poppet and piston-type valves,
43
poppet valves
flow, 122
momentum force, 120122
pressure flow
characteristics,
122123

Index 287

pressure compensated valves,

5658
pressure control valves
counterbalance cartridge
type, 4748
extending actuator
controlled, 49
flow characteristics, 4849
operating pressures, 5051
pressure reducing valves,
4647
relief valves
single-stage, 4345
two-stage, 4446
types, 43
proportional control valves,
5455
relief valves
single-stage, 4345
two-stage, 4446
restrictor valves, 5556
three-position valves, 7879
two-position valves, 7677
two-stage relief valves, 4446
Vane pumps and motors
fixed displacement units, 89
variable displacement unit,
910
Vane rotary actuator, 3940
Variable displacement pump
control
accumulator charging, 9899
load-sensing, 96, 97
power control, 9698
Variable displacement unit
axial piston, 1011
bent axis type axial piston
motor, 1112
pump port plate, 1011
vane pumps, 910
Vehicle crusher unloading pump
circuit, 246247

Vehicle transmission
data, 240
fluid viscosity effects, 242
pressure and flow, 241242
pump controls, 243245
steady state pump power
control analysis,
245246
vehicle speed, 241
Velocity control
bleed-off control, 8384
four-way valve restrictive
control (see
Four-way valve
restrictive control)
meter-in control, 8082
meter-out control, 8283
Viscous friction torque,
132133
W
Winch application
hydraulic motor
gear box, 205206
minimum motor
displacement,
208
motor data and selection,
206207
load lifting and lowering, 204
numerical values, 205
Wind turbine
benefits and limitations,
189190
calculated values, 259261
component details, 258259
speed control, 192193
system analysis, 259
torque and speed relationship,
190192
Wind turbines, 105106