How to Synchronize Multiple Hydraulic Cylinders

Multiple hydraulic cylinders do not stay synchronized automatically because loads, friction, leakage, geometry and component tolerances differ. Synchronization may use mechanical linkage, flow dividers, master-slave displacement, rephasing cylinders, position sensors or closed-loop electrohydraulic control. The correct method depends on allowable position error and fault behavior.

This guide supports industrial engineering and procurement. Follow the machine manufacturer’s instructions and qualified safety procedures. Explore Zhenqiang Hydraulic.

Define the synchronization requirement

Specify cylinder count, stroke, load distribution, speed, permitted position error and whether correction is continuous or only at end of stroke.

Identify consequences of one cylinder stopping, leaking or reaching its limit early. Structural racking can create severe side loads.

Compare synchronization methods

Mechanical linkage directly constrains relative motion but adds structure. Flow dividers split flow, yet accuracy changes with load and leakage.

Rephasing circuits periodically resynchronize matched cylinders. Position sensors with proportional or servo valves can provide closed-loop correction for tighter accuracy.

Match cylinders and machine geometry

Use matched bore, rod, stroke, installed lengths, mounts and plumbing where the architecture requires it. Equal nominal cylinders do not guarantee equal movement.

Balance structural stiffness and load distribution. A flexible frame or unequal linkage can defeat hydraulic matching.

Commission and monitor the system

Bleed air, verify sensor calibration and cycle slowly without critical load. Measure position error through the full stroke under representative loading.

Test fault response, relief behavior, load holding and safe shutdown. Record acceptance limits and a resynchronization procedure.

Practical reference

Method	Typical characteristic
Mechanical linkage	Direct geometric constraint
Flow divider	Moderate hydraulic matching
Master-slave	Displacement-based relationship
Rephasing cylinders	Periodic end-of-stroke correction
Closed-loop sensors	Continuous electronic correction

Information to document

• Machine manufacturer, model, serial range and cylinder function.
• Controlled drawing, part number, photographs and verified dimensions.
• Pressure, force, flow, speed, duty cycle, fluid and temperature.
• Mounting, load direction, environment and observed failure history.
• Quantity, acceptance tests, documentation and delivery destination.

Read more in the Hydraulic Cylinder Knowledge Center.

Frequently asked questions

Will identical cylinders move together?

Not exactly; load, friction, leakage and geometry create differences.

Can one flow divider synchronize four cylinders?

Only with a validated architecture, capacity, accuracy and fault analysis.

When is position feedback needed?

When allowable error is tighter than passive methods can maintain.