Control Components in Hydraulic Systems

9/18/2010
Fluid Power
Systems
CONTROL COMPONENTS IN
HYDRAULIC SYSTEMS
UNIT - 2
Notes.NieRoyalMech.com
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Systems
Hydraulic Valves
Fluid power is controlled prim arily through the use of valves
Selection of these valves involves not only the type but also the
size, actuating technique and rem ote control capability
There are three basic types of valves:

1. Directional control valves
2. Pressure control valves
3. Flow control valves
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Fluid Power
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Directional control Valves
Check Valve
Directional Control Valves control the direction of fluid flow in a circuit.

The simplest DCV is a Check Valve as shown in figure above. A check
valve allows flow in one direction, but blocks flow in the opposite
direction.
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Pilot-operated Check Valve
It permits free flow in one direction but permits flow in the normally
blocked opposite direction only if pilot pressure is applied at the pilot
pressure port of the valve
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Three-way Valve
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Three-way Valve
The radial clearance between the land of

the spool and bore is around 5-10 m
The spool can be positioned manually,

mechanically, by using pilot pressure, or
electrical solenoids
Three-way valves are typically used to

control the flow directions to and from
single-acting cylinders
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Valve Actuation Methods
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Four-way Valve
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Four-way Valve
Four-way valves are typically used to

control the flow directions to and
from double-acting cylinders
The graphic symbol shows only one

tank port T even the actual valve m ay
have two, as shown in the schem atic
drawing
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Manually Actuated Valves
Manually actuated two-position,

spring offset, four-way valve
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Manually Actuated Valves
Manually actuated, spring centered, three position,

four-way valve
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Mechanically Actuated Valves
Mechanically actuated, spring offset,

two-position, four-way valve
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Air-pilot - Actuated Valves
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Solenoid - Actuated Valves
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Solenoid - Actuated Valves
The most common method of actuating a spool valve is by using
solenoids
When an electric coil (solenoid) is energised, it creates a magnetic force

that pulls the armature into the coil. This causes the armature to push on
the push pin to move the spool of the valve
Solenoid valve has a flow capacity of 50 litres/min and a maximum

operating pressure of 250 bars
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Centre Flow Path Configurations
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Most three position valves have a variety of possible flow path

configurations, each suited for a particular application
An open-centre type connects all ports together. Pump flow can return
directly back to the tank at essentially atmospheric pressure. At the same
time, the actuator can be moved freely by applying an external force
In closed centre design, all ports are blocked and pump flow can be used
for other parts of the circuit. At the same time, the actuator connected to
ports A and B is hydraulically locked. Very often, closed centre design
forces the pump to produce flow at the high pressure setting of the
pressure relief valve. This not only wastes pump power, but heats up oil
and promotes wear and shortens pump life.
The tandem design also results in a locked actuator. However, it also

unloads the pump at essentially atmospheric pressure.
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Shuttle Valves
Shuttle valve consists of a floating piston that can be shuttled to one
side or the other of the valve depending on which side of the piston has
the greater pressure
Shuttle valves may be spring loaded (biased) in one direction to favour

one of the supply sources or unbiased as shown in figure so that
direction of flow through the valve is determined by circuit conditions
One application of shuttle valve is for safety in the event that the main
pump can no longer provide hydraulic power to operate emergency devices.
The shuttle valve will shift to allow fluid to flow from a secondary backup
pump.
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Pressure control Valves
Pressure control valves control the m axim um pressure level

in a hydraulic circuit, which provides control of the
m axim um output force or torque.
They also protect the circuit from excessive pressure, which

could dam age components and possibly cause serious
injury.
Pressure control valves m ay control the m aximum pressure

of the entire circuit, or sim ply one branch of the circuit.
Types of pressure control valves

1.Pressure Relief Valves,
2.Unloading Valves
3.Pressure Reducing Valves,
4.Sequence valves
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Simple Pressure Relief Valve
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Simple Pressure Relief Valve
It is a norm ally closed valve whose function is to lim it the

pressure to a specified m axim um value by diverting pump flow
back to the tank
When the system pressure reaches the pre-set value, the

resulting hydraulic force exceeds the spring force and the poppet
is forced off its seat. This perm its the flow through the outlet to
the tank
The pressure relief valve provides protection against any

overloads experienced by the actuators in the hydraulic system .
Obviously, one im portant function of a pressure relief valve is to
lim it the force or torque produced by hydraulic cylinders and
m otors
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Compound Pressure Relief Valve
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Pressure Reducing Valve
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Pressure Reducing Valve
This valve (normally open) is used to maintain reduced pressure in

specified location of hydraulic system
It is actuated by downstream pressure and tends to close as this pressure

reaches the valve setting. If downstream pressure is below the valve
setting, fluid will flow freely from the inlet to the outlet
There is an internal passageway from the outlet, which transmits outlet

pressure to the spool end opposite the spring. When the outlet
(downstream) pressure increases to the valve setting, the spool moves to
the right to partially block the outlet port
Then, just enough flow is passed to the outlet to maintain its present
pressure level.
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Unloading Valve
NVRs sketch for dummies (?)
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Unloading Valve
An unloading valve is used to unload the pump connected to port A when

the pressure at port X is maintained at the value that satisfies the valve
setting. The high flow poppet is controlled by the spring loaded piston and
the pressure applied to port X
Flow entering at port A is blocked by the poppet at low pressures. When

the pressure rises to the maximum value permitted by the adjustable
spring, the poppet lifts and flow goes from port A to port B
The pressure signal to port X acts against the control piston and moves it
further up. This opens the tank port and oil is discharged to the tank at
almost zero pressure, as long as pilot pressure is maintained
Hence, the pump has essentially no load. This is not the case with a
pressure relief valve because the pump is delivering full pump flow at the
pressure relief valve setting and thus is operating at maximum power
conditions
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Sequence Valve
NVRs sketch for dummies (?)
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Sequence Valve
A sequence valves primary function is to direct flow in a predetermined

sequence. It operates on the principle that when main system pressure
overcomes the spring setting, the valve spool moves up, allowing flow from
the secondary port
It may be direct or remote pilot operated
The pressure in the primary line is effective on the end of the spool. This
pressure will force the spool against the main bias spring and at the preset
value of the spring, allows passage from the primary to the secondary port
Ex: Clamp and feed sequence in sheet metal working

When the clamp cylinder moves out and clamps the workpiece, resistance
is met and pressure in the system increases. When the pressure reaches
the spring setting in the sequence valve, it opens, and flow is directed out
of the secondary port to operate the work cylinder
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Counterbalance Valve
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Counterbalance Valve
The purpose of a counterbalance valve (CBV) is to maintain control of a

vertical hydraulic cylinder to prevent it from descending due to the weight
of its external load
The primary port of this valve is connected to the bottom of the cylinder,
and the secondary port is connected to the DCV
The pressure setting of CBV is higher than is necessary to prevent the

cylinder load from falling due to its own weight
When pump flow is directed through DCV to the top of the cylinder, the
pressure in the CBV increases. Once this pressure reaches the pre-set
value, spool of CBV moves up and opens the path to DCV and then on to
the tank
When raising the cylinder, an integral check valve opens and allows free
flow for the upward motion of the cylinder
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Flow control Valves
Flow control valves control the flow rate of fluid in a circuit.
They accomplish this by incorporating a variable orifice into the circuit

that acts like a faucet, closing the flow control valve orifice reduces
the flow rate and opening the orifice increases the flow rate.
The speed of an actuator depend directly upon the flow rate in the
system. Controlling the flow rate therefore allows us to control the
speed of the actuator.
Needle valve
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Needle Valve
Q = C0A P/Sg
Where Q = volum e flow rate (m 3/sec)

C0 = a constant for the orifice
A = area of orifice opening (m 2)
P = pressure drop across the orifice (KPa)
Sg = specific gravity of oil
Since area A can be varied, we can rewrite the equation as,
Q = Cv P/Sg
Where Cv = AC0 = capacity co-efficient, where A is the area of

orifice when fully open
The value Cv is determ ined experimentally for each type of

valve in the fully open position and is listed as the rated Cv in
m anufacturers catalogues Notes.NieRoyalMech.com
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Needle Valve
Problem :
A needle valve is placed in the outlet line of a hydraulic system to

control the extension speed of the hydraulic cylinder. The load
acting on the cylinder during extension is 5000N. The following
data are available:
Desired cylinder speed = 0.25 m /sec

Cylinder piston diam eter = 5 cm
Cylinder rod diam eter = 2.5 cm
Specific gravity of oil = 0.9
Pressure relief valve setting = 35 bars
Determ ine the required capacity co-efficient of the needle valve
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Flow control Valves
Flow control valve (Needle valve with integral check valve)
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Flow control Valves
Non-pressure-compensated Valves
In this type, system pressure is

relatively constant and motoring
speeds are not too critical
They work on the principle that the

flow through an orifice will be constant
if the pressure drop remains constant
The design also involves a check

valve, which permits free flow in the
direction opposite to the flow control
direction
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Flow control Valves
Pressure-compensated Valves
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Flow control Valves
Pressure-compensated Valves
This design uses a hydrostat that maintains a constant 8-10 bars

differential across the throttle, whose orifice opening can be adjusted by an
external knob setting. The orifice area setting determines the flow rate to
be controlled
Hydrostat is held normally open by a light spring. It starts to close as inlet

pressure increases and overcomes the light spring force. This closes the
opening through the hydrostat and blocks of all flow in excess of throttle
setting.
As a result, the only oil that passes through the valve is the amount that 8-
10 bars can force through the throttle. Flow exceeding this amount can be
used by other parts of the circuit or diverted to the tank through PRV
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9/18/2010

Fluid power is controlled prim arily through the use of valves

There are three basic types of valves:

Directional Control Valves control the direction of fluid flow in a circuit.

The radial clearance between the land of

The spool can be positioned manually,

Three-way valves are typically used to

Four-way valves are typically used to

The graphic symbol shows only one

Manually actuated two-position,

Manually actuated, spring centered, three position,

Mechanically actuated, spring offset,

When an electric coil (solenoid) is energised, it creates a magnetic force

Solenoid valve has a flow capacity of 50 litres/min and a maximum

Most three position valves have a variety of possible flow path

The tandem design also results in a locked actuator. However, it also

Shuttle valves may be spring loaded (biased) in one direction to favour

Pressure control valves control the m axim um pressure level

They also protect the circuit from excessive pressure, which

Pressure control valves m ay control the m aximum pressure

Types of pressure control valves

It is a norm ally closed valve whose function is to lim it the

When the system pressure reaches the pre-set value, the

The pressure relief valve provides protection against any

This valve (normally open) is used to maintain reduced pressure in

It is actuated by downstream pressure and tends to close as this pressure

There is an internal passageway from the outlet, which transmits outlet

NVRs sketch for dummies (?)

An unloading valve is used to unload the pump connected to port A when

Flow entering at port A is blocked by the poppet at low pressures. When

NVRs sketch for dummies (?)

A sequence valves primary function is to direct flow in a predetermined

It may be direct or remote pilot operated

Ex: Clamp and feed sequence in sheet metal working

The purpose of a counterbalance valve (CBV) is to maintain control of a

The pressure setting of CBV is higher than is necessary to prevent the

They accomplish this by incorporating a variable orifice into the circuit

Where Q = volum e flow rate (m 3/sec)

Since area A can be varied, we can rewrite the equation as,

Where Cv = AC0 = capacity co-efficient, where A is the area of

The value Cv is determ ined experimentally for each type of

A needle valve is placed in the outlet line of a hydraulic system to

Desired cylinder speed = 0.25 m /sec

Determ ine the required capacity co-efficient of the needle valve

Flow control valve (Needle valve with integral check valve)

In this type, system pressure is

They work on the principle that the

The design also involves a check

This design uses a hydrostat that maintains a constant 8-10 bars

Hydrostat is held normally open by a light spring. It starts to close as inlet

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