Understanding Open Loop and Closed Loop Hydraulic Circuits

Knowing the difference between an open loop and a closed loop hydraulic circuit is vital when designing a hydraulic system. Each circuit type has unique characteristics that affect performance, cost, and application suitability.

We’ll review the distinctions between these two circuit types, covering their operation, components, and critical use cases.

What Is an Open Loop Hydraulic Circuit?

The term "open loop" refers to the continuous flow of hydraulic fluid that returns to the reservoir.

Key Components of an Open Loop Circuit

• Reservoir: Holds the hydraulic fluid, allowing it to cool and filter contaminants before recirculating.
• Pump: Often, a fixed displacement pump or a variable displacement pump draws fluid from the reservoir and pressurises it for the system.
• Directional Control Valve: Regulates fluid flow to actuators, such as hydraulic cylinders or motors.
• Actuator: Converts hydraulic pressure into mechanical motion.
• Relief Valve: Protects the system from excessive pressure spikes by diverting fluid back to the reservoir.

How an Open Loop Hydraulic Circuit Works

In this system, fluid flows from the reservoir to the hydraulic pump, through control valves to the actuators, and back to the reservoir. The reservoir is crucial in managing the fluid's temperature and eliminating air bubbles or contaminants. This type of circuit allows for a relatively straightforward system design and is commonly used in hydraulic presses, agricultural machinery, and other mobile equipment.

What Is a Closed Loop Hydraulic Circuit?

A closed loop hydraulic circuit differs significantly in design and operation. Instead of returning fluid to a reservoir after passing through the actuator, fluid circulates continuously between the pump and the actuator. This "closed" design reduces the volume of hydraulic fluid needed and improves system efficiency.

Key Components of a Closed Loop Circuit

• Hydraulic Pump: Typically, a variable displacement pump with a swash plate adjusts flow and pressure to match system demands.
• Charge Pump: Maintains system pressure and compensates for fluid losses, ensuring consistent operation.
• Directional Control Valve: Regulates fluid direction and flow between the pump and actuator.
• Actuator: Typically, hydraulic motors are also used with cylinders in some systems.
• Heat Exchanger: Removes excess heat generated in the closed circuit.

Operation of a Closed Loop Hydraulic Circuit

In a closed loop, fluid flows directly between the pump and the actuator without passing through a large reservoir. The charge pump compensates for any small fluid losses by drawing fluid from a smaller reservoir to maintain consistent pressure. This configuration is highly efficient and is often used in systems that require precise control over speed and direction, such as mobile machines.

Open Loop vs Closed Loop Hydraulic Systems

The difference between an open loop hydraulic circuit and a closed loop hydraulic circuit lies in their fluid flow paths, system design, and operational characteristics. Here's how they compare:

Advantages of an Open Loop Hydraulic Circuit

1. Simplicity: Open loop systems have fewer components, making them easier to design and maintain.
2. Cost-Effective: Open loop circuits are generally less expensive, with more straightforward pumps and fewer specialised parts.
3. Versatility: Suitable for various applications, including industrial and mobile machinery.

Advantages of a Closed Loop Hydraulic Circuit

1. Efficiency: A closed loop design reduces energy losses, particularly in systems requiring continuous operation.
2. Compact Design: With less fluid and no need for a large reservoir, closed loop systems take up less space.
3. Precision Control: Ideal for applications where fine-tuned control of speed and direction is essential.

Challenges in System Design

Open Loop Hydraulic Circuit

One challenge of open loop systems is managing fluid temperature. The reservoir helps dissipate heat, but prolonged use can cause the fluid to overheat, leading to inefficiency. Air bubbles and contaminants are another concern, requiring regular maintenance of the reservoir and filters.

Closed Loop Hydraulic Circuit

Closed loop systems require careful calibration of the variable displacement pump and charge pump to maintain consistent pressure. Additionally, the lack of a large reservoir means that heat management often relies on external heat exchangers, adding complexity to the design.

Are There Other Types Of Hydraulic Circuits?

When exploring hydraulic circuits, it's essential to understand the difference between open loop and closed loop systems. In open loop systems, the hydraulic fluid flows in one direction, from the pump inlet to an actuator and back to the pump, without any feedback. This means that the pressure within the circuit is not regulated based on the system's performance. Conversely, closed loop systems utilise directional control valves and flow regulating valves to maintain desired pressure levels and adjust the direction of the fluid based on the work to be done.

The open loop configuration typically employs a piston pump where the actuator-return ports allow fluid to flow back to the pump but without feedback affecting the operation. In contrast, a closed loop and open loop hybrid can optimise performance by controlling the pressure within the system through real-time adjustments. Understanding the difference between open loop vs closed loop systems is crucial for selecting the correct system type for specific hydraulics applications.

Choosing the Right Circuit for Your Application

Selecting between an open loop hydraulic system and a closed loop hydraulic system depends on your application's needs. A closed loop system offers greater efficiency and performance for tasks involving heavy lifting, long periods of use, or precise motion control. Conversely, an open loop system is often the better choice if your priority is simplicity and cost.

At Hydrastore, we understand the demands of various hydraulic applications. Whether you need an open loop hydraulic circuit for industrial machinery or a closed loop hydraulic circuit for mobile equipment, our team can guide you in choosing and maintaining the ideal system.

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Posted by admin in category Hydraulic Systems Advice on Tuesday, 18th November 2025