Step 1 of 4

Application Requirements

Define the mechanical requirements: output force or torque, operating speed, duty cycle, and environmental conditions.

Actuator Type
↕️
Linear (Cylinder)
Push / pull motion. Hydraulic cylinder extends and retracts.
🔄
Rotary (Motor)
Continuous rotation. Hydraulic motor drives shaft.
Force & Speed Parameters
N
mm/s
mm
cyc/h
Operating Conditions
%
RPM
Environment & Temperature
°C
°C
Step 2 of 4

System Design Parameters

Adjust the target operating pressure. All system parameters recalculate in real time.

Target System Pressure
200
bar
System Pressure
50 bar100 bar200 bar320 bar480 bar
⚙️ Adjust pressure to determine optimal pump type
Cylinder Bore
-mm
Required bore diameter
Flow Rate (max)
-L/min
At operating speed
Pump Power
-kW
Including 85% sys. efficiency
Pump Displacement
-cc/rev
At drive speed
Heat Generation
-kW
At duty cycle
Reservoir Volume
-L
3× pump flow rule
Step 3 of 4

Component Selection

Catalog-matched components based on your calculated parameters. Select one per category.

Step 4 of 4

System Summary

Complete hydraulic system specification with schematic, bill of materials, and design notes.

Live Parameters
Actuator TypeLinear
Design Force-
System Pressure200 bar
Flow Rate-
Pump Power-
Bore Diameter-
Heat Load-
Reservoir-
ISO Cleanliness
Target Class-
Filter Rating-
Filter β-
Safety Factors
Load SF1.25
PRV Setting-
Pressure Ratio-
Circuit Preview

Hydraulic System Selector: Component Selection Guide

Hydraulic system component selection, pump type, directional control valves, actuator sizing, cylinder specification and fluid line design, requires a systematic approach for industrial automation, press machines, construction equipment and mobile hydraulics. This selector tool recommends optimal components from application requirements.

📋 How to Use This Calculator

  1. Select application type, Press, Crane/Lifting, Injection Moulding, Mobile Equipment or Industrial Automation.
  2. Enter required cylinder force (kN), stroke (mm) and operating speed (mm/s).
  3. Specify operating pressure range.
  4. View recommended cylinder bore, pump flow rate, motor power, valve size and line diameter results.

📐 Formula & Working Principle

Cylinder bore D = 2×√(Force/(π×P)). Required flow Q = (π/4×D²×v)/1000 L/min. Pump power P = Q×p/(600×η) kW. Line velocity: pressure lines <4 m/s, return lines <2 m/s, suction <1 m/s.

💡 Worked Example

Press: 100 kN force, 200 bar, 50 mm/s speed. Bore=80 mm. Flow Q=15.1 L/min. Pump power=5.9 kW → 7.5 kW motor.

❓ Frequently Asked Questions (FAQ)

Q: What are the types and applications of hydraulic pumps?

Gear pump: simple, low cost, fixed displacement, max 200–250 bar. Vane pump: smooth flow, 150–175 bar. Piston pump: high pressure 350–700 bar, variable displacement, for high-performance systems.

Q: Proportional valves vs servo valves: when to use which?

Servo valves: highest accuracy, fast response. Proportional valves: good accuracy (1–3%), lower cost. CNC machines, test rigs: servo. Industrial automation: proportional.

Q: What does an accumulator do?

Energy storage: handles peak demand. Emergency power: operates on pump failure. Pulsation damping: reduces pump flow ripple. Nitrogen pre-charge pressure: 60–90% of minimum system pressure.

Q: How should hydraulic oil contamination be controlled?

Target cleanliness per ISO 4406: servo systems 15/13/10, proportional 17/15/12, general 18/16/13. Take regular oil samples every 500 hours.

Q: How should heat generation and cooling be managed?

Total heat rejection ≈ 20–30% of input power. Ideal oil temperature: 40–60°C, maximum 70°C. Heat exchanger: shell-tube or plate type.