Design & Development of Double Acting Cylinder to Prepare Hydraulic Test Rig
Pranav Patil
Fluid power systems, particularly hydraulics, play a critical role in industrial applications, yet there is often a disconnect between theoretical education and practical skills. This paper presents the design, fabrication, and validation of a modular Hydraulic Trainer Kit focused on demonstrating the operation of a double-acting hydraulic cylinder (DAC) through basic control circuits. The kit integrates a hydraulic power pack, directional control valves, pressure relief valves, and quick-release couplings (QRCs) mounted on an aluminium T-slot profile plate for ease of reconfiguration. Key calculations for cylinder sizing, force, speed, and flow rates were performed at a design pressure of 50 bar, yielding an extension force of 6.28 kN. and retraction force of 4.71 kN. The system emphasizes safety, modularity, and educational value, bridging the gap between classroom theory and industry practice. Validation confirms reliable bidirectional motion control, making it suitable for engineering laboratories.