How It Works
The Synchronization Challenge
When multiple hydraulic cylinders must move together (parallel operation), differences in friction, load, and manufacturing tolerances cause them to move at different speeds. Without synchronization, cylinders will "get out of step" and potentially damage equipment or cause uneven motion.
Synchronization Methods
1. Flow Dividers (Rotary or Spool Type)
- Splits flow equally between multiple outlets
- Accuracy: Typically 2-5% over full stroke
- Errors accumulate over stroke length
- Cost-effective for moderate accuracy needs
2. Servo/Proportional Valves with Feedback
- Uses position sensors (LVDT, magnetostrictive) on each cylinder
- Electronic controller adjusts flow continuously
- Accuracy: 0.1-1% depending on system
- Higher cost, requires electronics and programming
3. Mechanical Linkage
- Physical connection between cylinders (beams, chains, cables)
- Accuracy: Very high if rigid connection
- Limited to specific geometries
- May add complexity and weight
Error Accumulation
For flow dividers, synchronization error accumulates over the stroke:
Total Error = Stroke x (Error% / 100) x Number of Cycles
Without periodic re-synchronization, error compounds over multiple strokes.
Selecting the Right Method
- Accuracy < 5%: Standard flow dividers usually sufficient
- Accuracy 1-5%: High-quality flow dividers or proportional valves
- Accuracy < 1%: Servo valves with position feedback required
- Accuracy < 0.1%: Mechanical linkage or high-end servo systems
Cylinder Synchronization Calculator
Analyze synchronization requirements and select the appropriate method for parallel cylinder operation. Compare flow dividers, servo valves, and mechanical linkage.
Cylinder Configuration
System Parameters
Load Distribution
Accuracy Requirements
Select Synchronization Method
Flow Divider
Servo Valve
Mechanical Link
Simulated Position Error
Flow Divider Requirements
Synchronization Error Analysis
Force Analysis
Methods Comparison
| Method | Accuracy | Meets Req? | Relative Cost |
|---|---|---|---|
| Flow Divider (Std) | 5% | -- | $ |
| Flow Divider (Hi-Q) | 2% | -- | $$ |
| Proportional Valve | 1% | -- | $$$ |
| Servo w/ Feedback | 0.5% | -- | $$$$ |
| Mechanical Linkage | <0.1% | -- | $$-$$$$ |
Recommendation
Based on your requirements, a standard flow divider should provide adequate synchronization accuracy.
Reference
Error per Stroke:
Error = Stroke x (Accuracy% / 100)
Cumulative Error:
Total Error = Error x N_strokes (worst case)