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Hydraulic System

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(@techobby)
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Joined: 4 weeks ago
Posts: 3
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Hi i am new to the forum can someone give me some wiring and programing help to connect an IRF520 Mosfet switch and Arduino uno or any other smaller Arduino to activate the solenoid and the dumps for a a hydraulic system.

The green wire on the 3 prong switch connects to the solenoids, the white wire is the 24v wire that activates the solenoids from the 36v battery bank when the switch is pushed up or down the switch is spring loaded it returns back the center every time it is let go and the black wire connects to the dump the dump is there to return fluid back to the hydraulic pump and the solenoid is what activate the pump to raise the cylinders. 

Already in the Hydraulic system a switch is connected to the 24v in the 36v battery bank the switch makes the Hydraulic system go up and down if you hit the switch up it activate the 3 solenoids to raise what ever the cylinders are connected to raise it up and if you hit the switch down it activate the dump to lower what ever is connected to the cylinders the dump return fluid back to the the pump tank if you hold momentary switch and rock it back and forth what ever is connected to cylinders and the goes up and down.

What I want to with the Arduino uno or Nano I would prefer to use the Arduino Nano because its smaller than the Arduino uno is if I don't want to rock the switch switch back and forth I can just push a button that makes it go back and forth for a few seconds or a minute then stop. 

Hydraulic System


   
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robotBuilder
(@robotbuilder)
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Joined: 7 years ago
Posts: 2571
 

@techobby

Essentially you want to replace the self centering toggle switch with mosfets controlled by a program that executes when a button is pressed?

What are the three 24v solenoids i/o connected to? They all turn on/off together?

You would need two MOSFETs and other components to replace the toggle switch controlling inductive loads.

What 24v device is the dump wire connected to?

More information saves having a guessing game as I personally don't know what the Hydraulic system involves.

 



   
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robotBuilder
(@robotbuilder)
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Joined: 7 years ago
Posts: 2571
 

A google search on the image:

This diagram illustrates a 36-volt system specifically designed for hydraulic pumps, often used in lowrider vehicles or heavy machinery.

The setup uses three 12-volt batteries connected in series to achieve a total voltage of 36V, creating distinct 12V, 24V, and 36V power points.

The pump receives high-voltage power (36V) for operation, while a separate "dump wire" (often 24V) is used to activate the hydraulic release valve.

Proper grounding is essential for this system, with the negative terminal of the first battery serving as the main ground point.

And an image search:
https://www.layitlow.com/threads/switch-wiring-q.184799/?utm_source=google&utm_medium=organic

Bit of search for the dump pump.

https://forceamerica.com/understanding-dump-pumps

 



   
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(@techobby)
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Joined: 4 weeks ago
Posts: 3
Topic starter  

 

@robotbuilder Thanks for your reply but I am not seeking a way to control the hydraulic system by replacing the center off toggle switch what I want to do is connect an Arduino to the switch panel already connected to the system so one push of a button using the Arduino can control the front and rear cylinders to go up and down for a few seconds or one minute.

The wire for the 3 solenoids is connected to the switch when the switch is pushed up there is a pole inside of the switch that makes a connection to the bottom side of the switch the wire from that pole of the switch goes to the solenoids and when the switch is pushed down the pole inside of the center off switch now moves up to that pole of the switch, the dump wire goes to that pole of the switch so the car can go down.

Switch pushed up pole goes down to activate the solenoids switch pushed down pole goes up inside of the center off toggle switch to activate the dump to make the car go down. 

Again I want to do is connect an Arduino to the switch panel already connected to the system so one push of a button using the Arduino can control the front and rear cylinders to go up and down for a few seconds or one minute.

4 Prong Switch
Dump
System
Switch Wiring
Solenoid


   
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robotBuilder
(@robotbuilder)
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Joined: 7 years ago
Posts: 2571
 

@techobby 

Ok it is to do with a car suspension system. Over the last 8 months I have been helping a friend renovate an old '70s car although unlike him I am not a car man myself. We often turned to ChatGPT for help. You might get better results then here as I notice a lack of responses to your query. Keep in mind AI can give you incorrect information with full confidence it knows what is doing!! This forum does not paste text diagrams very well but you will find chatGPT does. I would have to copy paste using the text icon for each example which I haven't time to do.

This is a copy paste of output when I copied your question to ChatGPT.

Good luck with your project 👍 

Yes — what you’re describing is essentially automating the existing momentary center-off hydraulic switches, rather than replacing the hydraulic control system.

From your description, the switch works like this:

  • Center position: nothing is energized.
  • Switch UP: the internal contact connects the common/pole to the lift/solenoid circuit.
  • Switch DOWN: the internal contact connects the common/pole to the dump circuit.
  • You want the Arduino to simulate those switch actions for a programmed amount of time.

A good way to approach it is not to connect the Arduino pins directly to those solenoid wires. The Arduino should control an electrically isolated relay/interface, and that interface should make the same connections that the physical switch makes.

Conceptually

 
 
EXISTING HYDRAULIC SWITCH
┌─────────┴─────────┐
│ │
LIFT CONTACT DUMP CONTACT
│ │
└───────┬───────────┘
Hydraulic system
 

You could add an Arduino-controlled interface alongside the switch:

 
 
ARDUINO
┌─────────┴─────────┐
│ │
Relay/interface Relay/interface
for LIFT for DUMP
│ │
└─────────┬─────────┘
HYDRAULIC CONTROL
 

 

The important part is that the Arduino would effectively tell the relay:

"Close the same circuit as UP for 5 seconds."

Then:

"Open it."

And for lowering:

"Close the same circuit as DOWN for 5 seconds."

Then:

"Open it."

One important issue

Before choosing the relays, we need to know what voltage and current are actually present on those switch wires.

For example, if this is a typical 12-V automotive hydraulic system, the switch might be switching 12 V directly to solenoid coils. But we shouldn't assume that. We need to identify:

  1. Voltage on the switch common.
  2. Voltage appearing on the lift wire when UP is pressed.
  3. Voltage appearing on the dump wire when DOWN is pressed.
  4. Current drawn by the solenoids.
  5. Whether the front and rear solenoids are all operated by the same switch circuit or whether there are separate circuits.
  6. Whether the switch is momentary or latching.

Also, because this is an automotive hydraulic suspension system, I'd strongly recommend designing in electrical interlocks so the Arduino cannot accidentally command conflicting hydraulic functions at the same time.

For example:

 
 
Arduino
┌───────┴───────┐
│ │
LIFT RELAY DUMP RELAY
│ │
└───────┬───────┘
NEVER BOTH ON
 

And ideally retain the original physical switches as a manual override.

If you can give me a photo of the back of the switch showing all the terminals/wires, plus tell me the car/suspension system voltage (probably 12 V) and what the 3 solenoids do, I can map out exactly how I would wire the Arduino, relays, and existing switches.

 

That diagram helps a lot. It appears to be a 24-volt control system, and the important thing is that the Arduino should not be connected directly to the colored solenoid wires.

From the diagram, I see a 24 V constant-power feed (red) going to the switches, with the switches sending that 24 V to the appropriate solenoid/pump wires.

What I think your existing switches are doing

The switches appear to be center-off momentary switches. Conceptually, each one is:

 
 
24 V CONSTANT
[ COMMON ]
CENTER-OFF
/ \
/ \
UP DOWN
│ │
│ │
PUMP/LIFT DUMP
OUTPUT OUTPUT
 

So when you push the switch UP, the common terminal connects to the lift/pump output.

When you push it DOWN, the common terminal connects to the dump output.

When released, neither output is connected to 24 V.

That is actually a very good arrangement for Arduino control because we can make the Arduino electrically imitate those switch contacts.


The Arduino should act like another set of switches

For example, suppose you wanted the Arduino to control the front:

 
 
EXISTING SWITCH
┌─────────────────┐
24 V ────────────────┤ COMMON │
│ │
│ UP ──────────┼──── Front pump
│ │
│ DOWN ──────────┼──── Front dump
└─────────────────┘
 
 
ARDUINO RELAYS
┌─────────────────┐
24 V ────────────────┤ COM │
│ │
│ NO ─────────────┼──── Front pump
└─────────────────┘
 
┌─────────────────┐
24 V ────────────────┤ COM │
│ │
│ NO ─────────────┼──── Front dump
└─────────────────┘
 
 

The Arduino would energize the appropriate relay for however long you specify.

For example:

Front UP button pressed once:

 
 
Arduino
Front UP relay ON
5 seconds
Front UP relay OFF
 

Front DOWN button pressed once:

 
 
Arduino
Front DOWN relay ON
5 seconds
Front DOWN relay OFF
 

You could make that 1 second, 5 seconds, 10 seconds, 30 seconds, 60 seconds, etc.


But your diagram shows something important

I would not build the Arduino circuit yet, because your diagram appears to have considerably more than the "3 solenoids" you originally mentioned.

I can see these outputs:

  • DFR — Dump Front Right
  • DFL — Dump Front Left
  • DBR — Dump Back Right
  • DBL — Dump Back Left
  • PF — Pump Front
  • PB — Pump/Back

And there are apparently several switches controlling combinations of those outputs.

So the Arduino could potentially give you quite sophisticated control, such as:

Front

 
 
FRONT UP
→ PF ON
→ wait X seconds
→ PF OFF
 
FRONT DOWN
→ DFR + DFL ON
→ wait X seconds
→ DFR + DFL OFF
 

Rear

 
 
REAR UP
→ PB ON
→ wait X seconds
→ PB OFF
 
REAR DOWN
→ DBR + DBL ON
→ wait X seconds
→ DBR + DBL OFF
 

And potentially:

Individual corners

 
 
FRONT RIGHT UP
FRONT RIGHT DOWN
 
FRONT LEFT UP
FRONT LEFT DOWN
 
BACK RIGHT UP
BACK RIGHT DOWN
 
BACK LEFT UP
BACK LEFT DOWN
 

If the existing switches already accomplish these functions, the Arduino can reproduce exactly those same combinations.


I would use relays rather than connecting Arduino pins to the 24 V system

Something like this:

 
 
ARDUINO
┌──────────────┼──────────────┐
│ │ │
Relay 1 Relay 2 Relay 3 ...
FRONT UP FRONT DOWN REAR UP
│ │ │
│ │ │
24 V 24 V 24 V
│ │ │
↓ ↓ ↓
Existing lift Existing dump Existing lift
circuit circuit circuit
 

The relay contacts handle the 24 V control circuit.

The Arduino only controls the relay coils.

That gives us isolation between the Arduino's 5 V electronics and the hydraulic system's 24 V wiring.

One very important safety feature

The software should prevent UP and DOWN for the same circuit from being active simultaneously.

For example:

 
 
FRONT
┌───────┴───────┐
│ │
FRONT UP FRONT DOWN
RELAY RELAY
│ │
└──── NEVER ────┘
ON TOGETHER
 

I'd actually go one step further and use electrical interlocking in addition to the Arduino software. That way, a software failure can't accidentally activate lift and dump simultaneously.


Your 24 V system also changes the relay selection

Don't buy a relay board just because it says "Arduino relay module."

We need to know the actual current being switched by each switch circuit.

The relay contacts need to be rated for the voltage and current of the hydraulic control circuit. Since the solenoids are inductive loads, we also need appropriate suppression/protection.

And because this is 24 V, the Arduino's power supply needs to be handled separately — typically a suitable automotive DC-DC converter rather than putting 24 V directly onto the Arduino.


I think the next step should be to map your switches exactly

The image gives me the overall circuit, but I need to know which physical switch terminals correspond to which wires.

If you can take a clear photo of the back of the actual switch panel, showing the terminals and wires, I can help you identify:

  1. 24 V common
  2. UP/lift contact
  3. DOWN/dump contact
  4. Which wires are DFR, DFL, DBR, DBL, PF and PB
  5. Where the Arduino-controlled relay contacts should be connected
  6. How to make a single Arduino button press run the function for a selectable number of seconds
  7. How to retain the original manual switches
  8. How to prevent simultaneous UP/DOWN commands

If you send me a photo of the back of the switch panel and the individual switches, I can work through the wiring with you before you connect anything.



   
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(@techobby)
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Joined: 4 weeks ago
Posts: 3
Topic starter  

OK thanks i check chatgbt to see if it can show me a picture of the Arduino with wires going to it are connected to the switches panel and also power for the Hydraulics switches run on 24v to activate the solenoids then higher volts like 36v to 48v or higher go to the out put of the solenoid also known as a relay to power up the motor.   



   
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