Control components in Hydraulic system

One of the most important functions in any fluid power system is control. If control
components are not properly selected, the entire system will fail to deliver the required
output. Elements for the control of energy and other control in fluid power system are
generally called “Valves”. It is important to know the primary function and operation of
the various types of control components. This type of knowledge is not only required for
a good functioning system, but it also leads to the discovery of innovative ways to
improve a fluid power system for a given application
The selection of these control components not only involves the type, but also the
size, the actuating method and remote control capability. There are 3 basic types of
valves.
1. Directional control valves
1. Pressure control valves
2. Flow control valves.
Directional control valves are essentially used for distribution of energy in a fluid
power system. They establish the path through which a fluid traverses a given circuit. For
example they control the direction of motion of a hydraulic cylinder or motor. These
valves are used to control the start, stop and change in direction of flow of pressurized
fluid.
Pressure may gradually buildup due to decrease in fluid demand or due to sudden
surge as valves opens or closes. Pressure control valves protect the system against such
overpressure. Pressure relief valve, pressure reducing, sequence, unloading and
counterbalance valve are different types of pressure control valves.
In addition, fluid flow rate must be controlled in various lines of a hydraulic circuit.
For example, the control of actuator speeds depends on flow rates. This type of control is
accomplished through the use of flow control valves.

Directional control valves

As the name implies directional control valves are used to control the direction of
flow in a hydraulic circuit. They are used to extend, retract, position or reciprocate
hydraulic cylinder and other components for linear motion. Valves contains ports that are
external openings for fluid to enter and leave via connecting pipelines, The number of
ports on a directional control valve (DCV ) is usually identified by the term “ way”. For
example, a valve with four ports is named as four-way valve.
Directional control valves can be classified in a number of ways:
1. According to type of construction :
• Poppet valves
• Spool valves
2. According to number of working ports :
• Two- way valves
• Three – way valves
• Four- way valves.
3. According to number of Switching position:
• Two – position
• Three - position
4. According to Actuating mechanism:
• Manual actuation
• Mechanical actuation
• Solenoid ( Electrical ) actuation
• Hydraulic ( Pilot ) actuation
• Pneumatic actuation
• Indirect actuation
The designation of the directional control valve refers to the number of working
ports and the number of switching positions.
Thus a valve with 2 service ports and 2 switching positions is designated as 2 / 2
way valve. A

P
Fig 4.1. 2 /2 valve symbol

A valve with 3 service ports and 2 position is designated as 2 / 3 way valve.

A

P T
Fig 4.2. 2 / 3 valve symbol
A valve with 4 service ports and 2 position is designated as 2 / 4 valve.
A B

P T
Fig 4.3. 2 / 4 valve symbol

A valve with 4 Service ports and 3 Switching position is designated as 3 / 4 way

valve. Fig 4 shows an example of open centered position.
A B

P T
Fig 4.4. 3/ 4 valve symbol :

Spool positions as well as their corresponding actuating elements are labelled

with numbers 1, 2 as shown in figure 5. A valve with 2 spool position is shown and
also a valve with 3 spool positions. In directional control valves with 3 spool position,
the central position is the neutral position ( or mid position or zero or null position ).
The neutral position is the position in which the moving parts are assumed to be
inactive, but affected by a force (e.g. spring )
The ports are designated as follows:
P = Pressure Port ( Pump Port )
T = Tank Port
A , B = User Ports

1 2 1 0 2

2- Position valve 3- Position valve

Fig 4.5. Basic symbol for directional control valves
 Observe that the graphical symbol shows only one tank port T even though
the physical design may have two since it is only concerned with the function of a
component and not its internal design. The tank port is the port of the valve that is piped
back to the hydraulic oil tank. Therefore, each tank port provides the same function. The
spool valve working ports are inlet from the pump, outlets to the cylinder, and exhaust to
tank. These ports are generally identified as follows : P = pressure ; A or B = actuator
and T = tank.
1. Poppet Valves: Directional poppet valves consists of a housing bore in which one
or more suitably formed seating elements ( moveable ) in the form of balls, cones
are situated. When the operating pressure increases the valve becomes more tightly
seated in this design. The main advantage of poppet valves are;
- No Leakage as it provides absolute sealing.
- Long useful life, as there are no leakage of oil flows.
- May be used with even the highest pressures, as no hydraulic sticking (pressure
dependent deformation ) and leakages occurs in the valve.
The disadvantages of these valves are;
- Large pressure losses due to short strokes
- Pressure collapse during switching phase due to negative overlap ( connection of
pump, actuator and tank at the same time ).
2 / 2 DCV (Poppet design) :-

A A

P P
a. Valve Closed b. Valve Opened
Fig 4.6. 2 / 2 DCV Poppet Design
Figure 4.6a. shows a ball poppet type 2 / 2 DCV. It is essentially a check valve as
it allows free flow of fluid only in one direction (P to A) as the valve is opened
hydraulically and hence the pump Port P is connected to port A as shown in fig b. In the
other direction the valve is closed by the ball poppet ( note the fluid pressure from A
pushes the ball to its seat) and hence the flow from the port A is blocked ( fig a.). The
symbol for this type of design is same as that of check valve.(fig 4.6c)
No flow

Free flow
Fig 4.6c. Symbol of 2/2 poppet valve ( Check valve )
 2. Spool valves: The spool valve consists of a spool which is a cylindrical member
that has large- diameter lands machined to slide in a very close- fitting bore of the valve
body. The spool valves are sealed along the clearance between the moving spool and
the housing. The degree of sealing depends on the size of the gap, the viscosity of the
fluid and especially on the level of pressure. Especially at high pressures ( up to 350 bar)
leakage occurs to such a extent that it must be taken into account when determining the
system efficiency. The amount of leakage is primarily dependent on the gap between
spool and housing. Hence as the operating pressure increases the gap must be reduced or
the length of overlap increased. The radial clearance is usually less than 20 µ. The
grooves between the lands provide the flow passage between ports.
1. Two-way valve ( 2/ 2 DCV):
Lever for manual actuation
Bore Port A Valve Body
Spring

Spool
Port P a) Valve closed

Port A
Spring

Port P b) Valve opened by actuation

Fig 4.7 Spool type 2 / 2 DCV
The simplest type of directional control valve is a check valve which is a two way
valve because it contains two ports. These valves are also called as on-off valves because
they allow the fluid flow in only in one direction and the valve is normally closed. Two –
way valves is usually the spool or poppet design with the poppet design more common
and are available as normally opened or normally closed valves. They are usually
actuated by pilot (Hydraulic actuation ) but manual, mechanical , solenoid actuated
design are also available. Figure 4.7 above shows Spool type 2 / 2 DCV manually
actuated. In Fig 4.7 a) the port P is blocked by the action of spring as the valve is
unactuated ( absence of hand force). Hence the flow from port P to A is blocked. When
actuated ( Presence of hand force ) the valve is opened, thereby connecting port P to A.
2. Three – way valve : A directional control valve primary function is
alternatively to pressurize and exhaust one working port is called three-way valve.
Generally, these valves are used to operate single- acting cylinders. Three-way
directional valves are available for manual, mechanical, pilot, solenoid actuation.
These valves may be two-position, or three -position. Most commonly they have
only two positions, but in some cases a neutral position may be needed. These valves
are normally closed valves ( i.e the pump port is blocked when the valve is not
operating ). The three-way valve ports are inlet from the pump, working ports , and
exhaust to tank. These ports are generally identified as follows : P=
pressure( Pump)port ; A or B = working port and T = tank port. Figure 4.8 (a) and
(b) shows the two position of the three – way valve actuated manually by a push
button.
a. Spool position 1: When the valve is actuated, the spool moves towards left . In
this position flow from pump enters the valve port P and flows out through the port
A as shown by the straight- through line and arrow ( fig a). In this position, port T
is blocked by the spool.
b. Spool position 0: when the valve is un-actuated by the absence of hand force, the
valve assumes this position by the action of spring In this position, port P is blocked
by the spool. Flow from the actuator can go to the tank from A to T as shown by
straight – through line and arrow ( Fig a ).
spool A Push button for manual
actuation

P T Valve Body
Fig a. 1 position: P to A , T blocked
spring Port A

Port P T b) 2 position : Valve closed

Fig 4.8 2 /3 DCV
Symbol 2/ 3 DCV : -
0 1
3. Four - way DCV: - These valves are generally used to operate cylinders and
fluid motors in both directions hydraulically. The four ways are Port P that is
connected to pump, tank port T, and two working ports A and B connected to the
actuator. The primary function of a four way valve is to alternately to pressurize and
exhaust two working ports A & B. These valves are available with a choice of
actuation, manual, mechanical, solenoid, pilot & pneumatic. Four-way valve comes
with two or three position. One should note that the graphical symbol of the valve
shows only one tank port even though the physical design may have two as it is only
concerned with the function.
3.1. Three positions, Four way valve : These type of DCV consists of three
switching position. Most three- position valves have a variety of possible flow path
configurations, but has identical flow path configuration in the actuated position
( position 1 and position 2)and different spring centered flow paths. When left end of
the valve is actuated, the valve will assume 1 position. In this position the port P to
connected to working port A and working port B is connected to T (in some design P
is connected to B, and A to T when left end is actuated ). Similarly when the right
end is actuated, the valve will assume 2 position. In this position port P is connected
to B and working port A to T. When the valve is un-actuated, the valve will assume
its center position due to the balancing opposing spring forces. It should be noted
that a three-position valve is used whenever it is necessary to stop or hold a actuator
at some intermediate position within its stroke range, or when multiple circuit or
functions must be accomplished from one hydraulic power source.
Three- position, four- way DCV have different variety of center
configurations. The common varieties are the open center, closed center, tandem
center, floating center, & regenerative center with open, closed and tandem are the
three basic types A variety of center configurations provides greater flexibility for
circuit design.

a.) Open center 3 / 4 DCV : In open- center circuit, all ports are open to each other
in the center position. When the valve is in open center position, the pump
flow is directed to the tank at atmospheric pressure. At the same time the
actuator can be moved freely by applying an external force. Open center valve
help to prevent heat buildup, and no work can be done by any part of the
system, as long as the valve remains in the center position, since the fluid always
follows the path of least resistance . This means that other auxiliary devices in
the system using pressure energy cannot function.
Figure 4.9 a,b,c. shows the three positions of 3 / 4 DCV. Fig 4.9a. shows
the valve is mid position i.e when the valve is deactuated. In fig 4.9 b. since the left
end of the valve is actuated , the valve assumes 1 position. Here port P is connected
to A and B is connected to T. In fig 4.9 c, since the right end of the valve is actuated ,
the valve assumes 2 position. Here port P is connected to B and A is connected to T.
 Port B A Spool
Bore

T Port P T
a ) Mid position : Open Center
Valve body Port B A

Actuation

T Port P T
b ) 1 Position , Flow : P to A & B to T

Port B A

Actuation

T Port P T

c) 2 position : Flow : P to B & A to T

 Fig 4.9 ( a, b, c ): 3 position- 4 way , open centered DCV
(Note : In Fig b & c spring not shown)

A B
0
1 2

P T
Fig 4.9d. Symbol : Open Center 3 / 4 DCV

b.) Closed Center 3 / 4 DCV :

Bore Spool
Port B A Spring

T Port P T
Mid Position: Closed Center
Fig 4. 10a. Closed Center 3 / 4 DCV
A B

1 0 2

P T
Fig 4.10b. Symbol
Figure 4.10 shows a closed center 3- position, 4 – Way DCV in its center position.
The working of the valve is similar to open center DCV and in actuated position the port
connection is identical. In closed center DCV all ports are closed to each other. Hence
the actuator connected to ports A and B is hydraulically locked and cannot be moved by
an external force In this position the pump flow must go over the relief valve when flow
is not being used for any other parts of the circuit. This forces the pump to produce flow
at the high pressure setting of the pressure relief valve. This not only waste pump design
power but promotes wear and shortens pump life. Also the temperature of oil is raised
due to heat buildup in the system. This promotes oil oxidation , viscosity drop, which
further raises the wear of parts and increased leakage. With this type of center in DCV,
when the valve actuates to switching position 1 or 2, two things may happen. If pressure
port ( P to working port A or B) opens first pressure in the system raises which is not
desirable, and if tank port open first pressure drops. Closed –center versions are used only
when multiple circuit or functions must be accomplished in the system from one power
source.
c.) Tandem centered 3 /4 DCV : Figure 4.11 shows a tandem center 3-position, 4-way
DCV. In the center configuration, the working ports A and B are blocked , and the pump
port P is connected to tank port T. The tandem center also results in a locked actuator.
However, it also unloads the pump at atmospheric pressure. The application of this
design may be to hold a cylinder or fluid motor under load or to permit the pump flow to
be connected to a series of valves for multiple circuitry.
Port B A Spool
Bore

T Port P T
Fig 4.11a. Tandem Center 3 / 4 DCV : Mid position
A B

1 0 2

P T
Fig 4.11b. Symbol

d.) Regenerative Center 3 / 4 DCV : This is another type of common center

configuration used in hydraulic circuits. Regenerative means the flow generated from the
system itself. Regenerative center is used whenever the actuator movement in one
direction requires two different speeds eg., Part of length of extending stroke of actuator
requiring fast movement during no load condition and remaining length slow controlled
motion. During fast extending the DCV is un-actuated thereby by spring forces it comes
to the mid position. This center saves on additional pump capacity required.
Fig 4.12 shows double acting single rod cylinder connected to 3 / 4 DCV having
regenerative center. The piston area(A) is more than ring area (B) . When the cylinder is
actuated by this type of DCV , in the center configuration, the pump flow is directed
towards A, since the piston area is more it offers least resistance( fluid flows always in
the path of least resistance ) and hence the fluid flows towards A. The return flow from B
also joins the pump flow, which increased the piston speed due to increased flow

Piston Piston Rod

Cylinder A B

A B

1 0 2

P T
Fig 4.12 Double acting cylinder connected to
Regenerative center 3 /4 DCV

Fig 4.13 shows Regenerative center type 3 / 4 DCV in its mid position. In the mid
position Pump Port P is connected to A and B, and tank port T is blocked.

Bore Spool
Port B A Spring

T Port P T
Mid Position
Fig 4. 13a. Regenerative Center 3 / 4 DCV
A B

1 0 2
:
P T
Fig 4.13b. Symbol

e.) Floating Center 3 / 4 DCV :

Bore Spool
Port B A Spring

T Port P T
Mid Position:
Fig 4. 14a. Floating Center 3 / 4 DCV
A B

1 0 2

P T
Fig 4.14b. Symbol :

Figure 4.14 shows floating center 3 / 4 DCV in its mid position. In this
position the pump port is blocked and the two working ports A and B are connected
to tank port T. Since the working ports A and B are connected to tank T, the actuator
can be moved freely without any external force and hence the name floating. In this
valve also like in closed center, in the mid position the pump flow must go over the
relief valve when flow is not being used for any other parts of the circuit. This
forces the pump to produce flow at the high pressure setting of the pressure relief
valve, which buildsup heat in the circuit. Hence this center configuration is used
only in special case.

3.2 Two- position, Four – way DCV : These valves are also used to operate double
acting cylinder. These valves are also called as impulse valve as 2 / 4 DCV has only
two switching positions, i.e it has no mid position. These valves are used to
reciprocate or hold and actuating cylinder in one position. They are used on
 machines where fast reciprocation cycles are needed. Since the valve actuator moves
such a short distance to operate the valve from one position to the other, this design
is used for punching, stamping and for other machines needing fast action. Fig 4.15 a
and b shows the two position of 2 / 4 DCV.

Bore Spool
Port B A

Actuation

T Port P T
a. 1 Position : P to A and B to T

Bore Spool
Port B A

Actuation

T Port P T

b. 2 Positon, P to B and A to T
Fig 4.15 : 2 / 4 DCV

1 2
11

Fig 4.15c. Symbol

 Actuation of Directional control valves : Directional control valves can be actuated
by different methods.
1. Manually – actuated Valve: A manually actuated DCV uses muscle power to
actuate the spool. Manual actuators are hand lever , push button, pedals . The
following symbols shows the DCV actuated manually

1 2

Fig 4.16.
Fig 4.16 shows the symbol of 2 / 4 DCV with manually operated by roller tappet to
1 and spring return to 2.

1 2

Fig 4.17
Fig 4.17 shows the symbol of 2 / 4 DCV with manually operated by hand lever to 1
and spring return to 2.
In the above two symbols the DCV spool is returned by springs which push the
spool back to its initial position once the operating force has stopped e.g, letting go of
the hand lever
2. Mechanical Actuation: The DCV spool can be actuated mechanically, by roller and
cam, roller and plunger. The spool end contains the roller and the plunger or cam can be
attached to the actuator (cylinder).. When the cylinder reaches a specific position the
DCV is actuated. The roller tappet connected to the spool is pushed in by a cam or
plunger and presses on the spool to shift it either to right or left reversing the direction of
flow to the cylinder. A spring is often used to bring the valve to its center configuration
when deactuated.
3. Solenoid-actuated DCV : A very common way to actuate a spool valve is by using a
solenoid is illustrated in Fig 4.18. When the electric coil (solenoid) is energized, it
creates a magnetic force that pulls the armature into the coil. This caused the armature to
push on the spool rod to move the spool of the valve.. The advantage of a solenoid lies
with in its less switching time.
 Energized Coil Spool
Armature Bore B A

Spool Rod T P T

Fig 4.18 Working of solenoid to shift spool of valve.

Figure 4.18 shows the working of a solenoid actuated valve when left coil is
energized, its creates a magnetic force that pulls the armature into the coil. Since the
armature is connected to spool rod its pushes the spool towards right. Similarly when
right coil is energized spool is moved towards left. When both coil is de-energized the
spool will come to the mid position by spring force Figure 4.16 a shows a symbol for
single solenoid used to actuate 2- position ,4 way valve and b) shows symbol for 2
solenoids actuating a 3- position valve, 4 way valve..

1 2

Fig 4.18 a) Symbol for Single solenoid-actuated , 2- Position,

4-way spring centered DCV
.
1 0 2

Fig 4.18 b) Symbol for Solenoid actuated, 3- position, ,

4- way spring centered DCV
4.Hydraulic actuation: This type actuation is usually known as pilot- actuated valve. The
hydraulic pressure may directly used on the end face of the spool . The pilot ports are
located on the valve ends. Fig 4.19a. shows a directional valve where the rate of shifting
the spool from one side to another can be controlled by a needle valve. Fluid entering the
pilot pressure port on the X end flows through the check valve and operates against the
piston. This forces the spool to move towards the opposite position. Fluid in the Y end
(right end ,not shown in the figure) is passed through the adjustable needle valve and
exhausted back to tank. The amount of fluid bled through the needle valve controls how
fast the valve will shift. Fig 4.19b. shows the symbol of pilot actuated 2 / 4 DCV.
Part of Valve Body
Needle valve Port

Spool

Pilot port X
Fig 4.19a. Pilot actuated DCV
A B

Y
X P T
Fig 4.19b.. Symbol for pilot actuated 2 /4 DCV

5. Pneumatic actuation : Directional control valve can also be shifted by applying air
pressure against a piston at either end of the valve spool. When air is introduced
through the left end passage ( X), its pressure pushes against the piston to shift the
spool to the right. Removal of this left end air supply and introduction of air through
the right end passage (Y) causes the spool to shift to the left. Figure 4.19 shows the
symbol for pneumatic actuated 2 / 4 DCV. Note that the shaded arrow represents the
pilot actuation as in fig 4.20 and the unshaded arrow represent pneumatic signal .

A B

X Y
P T
Fig 4.20. Symbol for Pneumatic actuated 2 / 4 DCV
6. Indirect actuation of directional control valve : We have seen that a directional
valve spool can be positioned from one extreme position to another by actuated it by
manually, mechanically, electrically ( solenoid) , hydraulic(pilot) and pneumatic. The
mode of actuation has no influence on the basic operation of these switching circuits.
However since there is usually not a lot of force available, direct actuation is
restricted to use with rather smaller valves. Especially with direct actuation, the
greatest disadvantage is that the force which can be developed by them to shift a
directional valve spool is limited. As a matter of fact, the force required to shift a
directional spool is substantial in the larger size.
Larger valves are often indirectly actuated in one after the other sequence.
First the smaller valve is directly actuated. Flow from the smaller valve is directed to
either side of the larger valve when shifting is required. The main DCV is referred as
pilot actuated DCV. The control oil can come from a separate circuit or from the
same system’s pressure line. Pressure for pilot valve operation is usually supplied
internally from the pressure passage in the main valve. These two valves are often
incorporated as a single unit. Therefore one may find it hard to see that it is an
indirectly controlled valve. These valves are also called as Electro-hydraulic operated
DCV.

Main( larger ) DCV , 3 / 4 closed

Center , pilot actuated
A B
X Y Control Signal
1 0 2

P T

A B

1 0 2

P T

Solenoid actuated
P Floating center 3 / 4 DCV
( Smaller valve )
 Fig 4.21a. Symbol for Indirect actuation
For 3 / 4 DCV

A B

1 0 2

P T

Fig 4.21b. Combined symbol :.Solenoid actuated internal pilot operated,

3 / 4 closed center DCV

Valve Lap: Valve lap is essential. It the sealing length that exist between various
pressure ports. It is achieved by the tolerance between the spool and the housing.
Compared to poppet valves, hermetic sealing is not possible. The seal effect is therefore
dependent on the dimension of the sealing aperture and the fluid viscosity. There are two
types of lap.
1. Lap in stationary condition: The leakage rate between various pressure port is
dependent on:
• Seal length between port and spool (S ) : If large lap is provided leakage is less, but
it increases the switching time. In servo valves S =0
• The spool play or clearance- It is clearance space ( C )between spool and the bore.
Large clearance means more leakage.The diameter of the spool.
• The pressure differential .

.
S Ports
Spool

Bore
 Fig 4.22: Seal Length Between port and spool

Ports
Spool

C Bore

Fig 4.23 : Clearance between spool and Bore

Note : C = 20µ
2. Lap during Switching or cross over condition in DCV: Two position directional
control valve can be equipped with a cross over center condition. This center
condition is what an actuator sees for a fraction of a second as the valve shifts from
one extreme to another. That is, it indicates how the port connection are established
during change over of the valve. Open and Closed center conditions are the most
frequently used cross over.
• Negative lap during switching ( or under lap ) - Open center cross over:
During changeover from one switching position to another switching position
momentarily all the ports are interconnected with one another. The advantage is there is
no switching impact i.e, no pressure peak . the disadvantage is that the pressure falls
momentarily which may lower the load , the accumulator is emptied etc.,

A B

1 2

P T
Fig 4.24 Open Center cross over
• Positive lap during switch over ( over lap) ; Closed center cross over:
During changeover from one switching position to another switching position
momentarily all the ports are blocked. Advantage: The valve does not allow the
system pressure to drop severely during a shift. As the directional valve shifts system
pressure is immediately present to reverse the actuator. The disadvantage is pressure
peaks momentarily in positive type of valve cross over This type can be lpressure
pre- opening and tank pre-opening.
a. Pressure pre- opening: During change over pressure port connection closes last
and it opens first in next switching position. It is mostly used for control of
hydraulic motors. It provides instant reversing.

A B

P T
Fig 4.25. Pressure pre- opening

b. Tank pre- opening: During change over tank port connection closes last and it
opens first in next switching position. It is used for control of cylinders with
differential areas ( decompression facility).

A B

P T
Fig 4.26. Tank pre- opening

In reversing, a high inertial loads, it is preferable to use open center cross

over which allows the actuator lines to bleed slightly before reversal takes place. If a
closed center cross over is used with this type of load, the inertia of the load, would
build up pressure in an actuator line which could be quite high.

----------------------------

PRESSURE CONTROL VALVE

These are the units ensuring the control of pressure. A throttling orifice is present in
the valve and by variation of orifice, the pressure level can be controlled or at a
particular pressure, a switching action can be influenced.
 Classification: Basically one differentiates between pressure regulating and pressure
switching valves. Pressure regulation valves are for maintaining a constant pressure in
a system. Pressure switching valves, apart from a definite control function they also
perform a switching action. Such valves not only provide a switching signal, as in the
case of pressure switches, but also operate themselves as a DCV type of switching
within the hydraulic system. In the case of pressure switching valves the piston or
spool of the valve remains at a definite position either open or closed depending on
the control signal (Yes or No ). The control signal is generally external to the valve.
In the case of pressure regulating valves the piston or spool takes up in between
position depending on the variable pressure and flow characteristics.
As in DCV these valves can also have the valve element either poppet or spool.. With

poppet the sealing is good. But small movement of poppet allows large flows thereby excessive drop

of pressure than required. This results is impact effect.

The spool type of valves allow very fine control or throttling of flows. But of course,
the sealing is not very good.
Opening and closing pressure difference:
The minimum pressure at which the valve action starts is called as the opening
or cracking pressure. The difference between the cracking pressure (commencement
of flow) and the pressure obtained at maximum flow ( normal flow without change of
spring force ) is referred as the “opening pressure difference”.
Similarly the difference between the pressure corresponding to nominal flow and no
flow during closing of the valve is referred as “closing pressure difference”. This is
larger than the opening due to the flow forces acting in the opening direction as also
the hysterisis in the spring.
Different types of pressure control valves: Pressure control valves are usually
named for their primary function such as relief valve, sequence valve, unloading
valve, pressure reducing valve and counterbalance valve.

1. Pressure Relief valve:

One of the most important pressure control is the relief valve. Its primary function
is to limit the system pressure. Relief valve is found in practically all the Hydraulic
system. It is normally a closed valve whose function is to limit the pressure to a
specified maximum value by diverting pump flow back to the tank. There are two
basic design, a) direct operated or inertia type, b) the pilot operated design
( compound relief valve ).

Direct type of relief valve: The direct type of relief valve has two basic working
port connection. One port is connected to pump and the other to the tank. The valve
consists of a spring chamber ( control chamber ) with an adjustable bias spring which
pushes the poppet to its seat, closing the valve. A small opening connecting the tank
is provided in the control chamber to drain the oil that may collected due to leakage,
thereby preventing the failure of valve. System pressure opposes the poppet, which is
held on its seat by an adjustable spring. The adjustable spring is set to limit the
maximum pressure that can be attained within the system. The poppet is held in
position by spring force plus the dead weight of spool. When pressure exceeds this
force, the poppet is forced off its seat and excess fluid in the system is bypassed back
to the reservoir. When system pressure drops to or below established set value, the
valve automatically reseats. Fig 4.27a shows a direct pressure relief valve. Fig 4.27b
shows the symbol.

Screw
(for pressure setting)

Spring Control
Chamber

Drain
(to remove oil from Poppet

Tank

Pump ( When Pressure here is less than

the valve setting, the valve is closed )
Fig 4.27a. Pressure Relief Valve

Fig 4.27b. Symbol

2. Unloading Valve: A unloading valve is used to permit a pump to operate at

minimum load. The unloading valve is normally closed valve with the spool closing
the tank port. It operates on the principle that pump delivery is diverted to the tank,
when sufficient pilot pressure is applied to move the spool against the spring force.
The valve is held open by pilot pressure until the pump delivery is again needed by
the circuit. The pilot fluid applied to move the spool upwards becomes a static
system. In other words, it merely pushes the spool upward and maintains a static
pressure to hold it open. When the pilot pressure is relaxed, the spool is moved down
by the spring, and flow is diverted through the valve into the circuit. The spool type
unloading valve is shown in fig 4.28. The valve consists of a spring chamber ( control
chamber ) with an adjustable bias spring which pushes the spool closing the tank
port. The valve has 2 ports one connecting the pump and other connecting the tank.
The movement of the spool inside the bore opens or closes the ports. Drain is
provided to remove the oil that may collect in control chamber due to leakage,
thereby preventing valve failure.
Unloading valves also helps to prevent heat buildup in a system, which is
caused by fluid being discharged over the relief valve at its pressure setting. The
unloading valve is used in system having one or more fixed delivery pump to control
the amount of flow at any given time. A well designed hydraulic circuit uses the
correct amount of fluid for each phase of a given cycle of machine operations. When
pressure builds up during the feed phase of the cycle, the pilot pressure opens the
unloading valve, causing the large discharge pump to bypass its flow back to the tank.

Screw
(for pressure setting)

Spring Control
Chamber

Drain

Tank

Pump

Remote
Pilot Pressure Signal
Fig 4.28b Unloading Valve

Fig 4.28a. Symbol

Problem 1. A pressure relief valve has a pressure setting of 69 bars. a) Compute
the hydraulic power loss across this valve if it returns all the flow back to the tank
from a 0.0013m3/s discharge pump. b) If unloading valve is used to unload the pump
and if the pump discharge pressure during unloading equals 1.72 bars, how much
power is being wasted ?

Solution :
b) Pressure setting, p= 69 bars = 69*105 N / m2 ;
Discharge, Q = 0.0013m3/ s
Power=?

We know, Hydraulic Power = p * Q watts

Hydraulic power loss = 69 *105 *0.0013 = 8970 watts Ans

b) Discharge pressure during unloading , p = 1.72 bars

Hydraulic power loss = 1.72*105 * 0.0013 = 223.6 watts Ans

One can see that by using unloading valve to unload the pump flow, the power
loss is very much less compared to that of relief valve.

3. Sequence valve: A sequence valve’s primary function is to divert flow in a

predetermined sequence. It is a pressure- actuated valve similar in construction to a
relief valve and normally a closed valve. The sequence valve operates on the principle
that when main system pressure overcomes the spring setting, the valve spool moves
up allowing flow from the secondary port.
A sequence valve may be direct or remote pilot- operated. These valves are used
to control the operational cycle of a machine automatically. Sequence valve may be
directly operated as shown in the fig 4.29b. The valve consists of a spring chamber
( control chamber ) with an adjustable bias spring for setting the pressure. It consists
of 2 ports, one main port connecting the main line and other (secondary port)
connected to the secondary circuit. Usually the secondary port is closed by the spool.
A small opening connecting the tank is provided in the control chamber to drain the
oil that may collected due to leakage, thereby preventing the failure of valve. The
pressure is effective on the end of the spool. This pressure will urge the spool against
the spring force and at the preset value of the spring it allows a passage from the
primary to the secondary port. For remote operation it is necessary to close the
passage used for direct operation by plugging and provide a separate pressure source
as required for the operation of the spool in the remote operation mode.
 Fig 4.29a. Symbol

Screw
(for pressure setting)

Spring Control
Chamber
Drain

Secondary Port

Pressure ( Main )
Line Spool

Direct Operation
(Control Signal)

Remote
Pilot operation
(Plugged) Fig 4.29b. Sequence valve

4. Counterbalance Valve: A Counterbalance valve is used to maintain back

pressure to prevent a load from failing. One can find application in vertical presses,
lift trucks, loaders and other machine tool that must position or hold suspended loads.
The counterbalance valve shown in the figure 4.30a. The valve consists of a
spring chamber ( control chamber ) with an adjustable bias spring which controls the
movement of spool. It has two ports, one connected to load and the other to the tank
A small opening connecting the tank is provided in the control chamber to drain the
oil that may collected due to leakage, thereby preventing the failure of valve.
Counterbalance valve acts on the principle that fluid is trapped under pressure until
pilot pressure, either direct or remote(only one opened at a time and other blocked ),
has to overcomes the spring force setting in the valve. Fluid is then allowed to escape,
letting the load to descend under control. This valve can be used as a “braking
valve” for decelerating heavy inertia load.
A counterbalance valve is normally closed valve and will remain closed until
acted upon by a remote pilot pressure source. Therefore, a much lower spring force is
sufficient to allow the valve to operate at a lesser pilot pressure.
 Screw
(for pressure setting)

Spring Control
Chamber
Drain

Load

Tank Spool

Direct Operation

Control signal Line

Remote
Pilot operation
(Plugged)

Fig 4.30a Counter Balance Valve

Direct pilot

Remote pilot

Fig 4.30b. Symbol

 When a counterbalance valve is used on large vertical presses, it may important
to analyze the source of pilot pressure. Figure 4.31 (a) and (b) illustrate the
comparison between direct and remote pilot signal

From Pump From Pump

To
Tank To Tank

200bar +

100 kN 100 kN

Fig 4.31a Direct Pilot Fig 4.31b. Remote pilot

Let Piston area, AP = 100 cm2 =0.01 m2

Ring area, AR = 50 cm2 = 0.005m2
Load , F = 100 kN = 100000 N
The pressure to support the load is therefore equal to ,
p = F / AR = 100000 / 0.005 = 20*106 N / m2 = 200 bar

Hence a pressure of 200 bar is needed to support the load. If pilot pressure is
taken directly as shown in fig 4.31a, then the counterbalance valve should open at
about 200 bar or slightly higher because of inertia and friction. Hence the spring
setting is about 200 bar or slightly higher. In other case ( fig 4.31b) if remote pilot
pressure is taken from the pressure line at the top of the cylinder, a choice of the
operating pressure can be made for the valve. Since the valve is normally closed
valve and will remain closed until acted upon by a remote pilot pressure source.
Therefore, a much lower spring force can be selected to allow the valve to operate at
a lesser pilot pressure.

5. Pressure Reducing Valve: Pressure reducing valve is used to limit its outlet
pressure. Reducing valves are used for the operation of branch circuits, where
pressure may vary from the main system pressures.
The pressure reducing valve is normally an open type valve. Figure 4.32 shows
the pressure reducing valve. The valve consists of a spring chamber ( control
chamber ) with an adjustable spring to set the pressure as required by the system. A
small opening is provided in the control chamber to drain the oil that may be
collected due to leakage, thereby preventing the failure of valve. A free flow passage
is provided through the valve from inlet to secondary outlet until a signal from the
outlet side tends to throttle the passage through the valve. The valve operates on the
principle that pilot pressure from the controlled pressure side opposes an adjustable
bias spring normally holding the valve open. When the two forces are equal, the
pressure downstream is controlled at the pressure setting. Thus, it can be visualized
that if the spring has greater force, the valves open wider and if the controlled
pressure has greater force, the valves moves towards the spring and throttles the
flow.
 Screw
(for pressure setting)

Spring Control Chamber

Drain

Pump Or Spool
Main Pressure
Side
Out
(Controlled Pressure )

Control Signal Line

Fig 4.32a Pressure Reducing Valve

Fig 4.32b. Symbol