Control Components in Hydraulic System
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
2. Pressure control valves
3. 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.
P
Fig 4.1. 2 /2 valve symbol
P T
Fig 4.2. 2 / 3 valve symbol
P T
Fig 4.3. 2 / 4 valve symbol
P T
Fig 4.4. 3/ 4 valve symbol :
1 2 1 0 2
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
P T Valve Body
Fig a. 1 position: P to A , T blocked
spring Port A
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
P T
Fig 4.9d. Symbol : Open Center 3 / 4 DCV
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
1 0 2
P T
Fig 4.11b. Symbol
Cylinder A B
A B
1 0
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
:
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
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
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
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
Bore
C Bore
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
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.
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 Poppet
Tank
Screw
(for pressure setting)
Spring Control
Chamber
Drain
Tank
Pump
Remote
Pilot Pressure Signal
Fig 4.28b
Unloading Valve
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
3
0.0013m /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 :
5 2
b) Pressure setting, p= 69 bars = 69*10 N / m
3
; Discharge, Q = 0.0013m / s
Power=?
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.
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
Screw
(for pressure setting)
Spring Control
Chamber
Drain
Load
Tank Spool
Direct Operation
Direct pilot
Remote pilot
To
Tank To Tank
200bar +
100 kN 100 kN
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)
Drain
Pump Or Spool
Main Pressure
Side
Out
(Controlled Pressure )