One of the most important considerations in any fluid power system is control.

If control components
are not properly selected, the entire system does not function as required. In fluid power, controlling
elements are called valves. There are three types of valves:
1. Directional control valves (DCVs): They determine the path through which a fluid transverses a
given circuit. Pressure control valves: They protect the system against overpressure, which may occur
due to a sudden surge as valves open or close or due to an increase in fluid demand.
2. Flow control valves: Shock absorbers are hydraulic devices designed to smooth out pressure surges
and to dampen hydraulic shock.
In addition, the fluid flow rate must be controlled in various lines of a hydraulic circuit. For example,
the control of actuator speeds can be accomplished through use of flow control valves. Non-
compensated flow control valves are used where precise speed control is not required because the flow
rate varies with pressure drop across a flow control valve. It is important to know the primary function
and operation of various types of control components not only for good functioning of a system, but
also for discovering innovative methods to improve the fluid power system for a given application.

Directional Control Valves

A valve is a device that receives an external signal (mechanical, fluid pilot signal, electrical or
electronics) to release, stop or redirect the fluid that flows through it. The function of a DCV is to
control the direction of fluid flow in any hydraulic system. A DCV does this by changing the position
of internal movable parts.
A DCV is mainly required for the following purposes:
 To start, stop, accelerate, decelerate and change the direction of motion of a hydraulic actuator.
 To permit the free flow from the pump to the reservoir at low pressure when the pump’s delivery is
not needed into the system.
 To vent the relief valve by either electrical or mechanical control.
 To isolate certain branch of a circuit.
Any valve contains ports that are external openings through which a fluid can enter and exit via
connecting pipelines. The number of ports on a DCV is identified using the term “way.” Thus, a valve
with four ports is a four-way valve A DCV consists of a valve body or valve housing and a valve
mechanism usually mounted on a sub-plate. The ports of a sub-plate are threaded to hold the tube
fittings which connect the valve to the fluid conductor lines. The valve mechanism directs the fluid to
selected output ports or stops the fluid from passing through the valve. DCVs can be classified based
on fluid path, design characteristics, control methods and construction
Classification of DCVs based Fluid Path : Based on fluid path, DCVs can be classified as follows:
 Check valves.
 Shuttle valves.
 Two-way valves.
 Three-way valves.
 Four-way valves.
Check Valve
The simplest DCV is a check valve. A check valve allows flow in
one direction, but blocks the flow in the opposite direction. It is a
two-way valve. Figure shows the graphical symbol of a check
valve along with its no-flow and free-flow directions.
Shuttle Valve
A shuttle valve allows two alternate flow sources to be connected in a one-branch circuit. The valve has two
inlets P1 and P2 and one outlet A. Outlet A receives flow from an inlet that is at a higher pressure. Figure
shows the operation of a shuttle valve. If the pressure at P1 is greater than that at P2, the ball slides to the
right and allows P1 to send flow to outlet A. If the pressure at P2 is greater than that at P1, the ball slides to
the left and P2 supplies flow to outlet A. A shuttle valve is called an “OR” valve because receiving a pressure
input signal from either P1 or P2 causes a pressure output signal to be sent to A.

Graphical symbol of shuttle valve

Shuttle valve: Flow from left to outlet and (b) flow from right to outlet
2/2-Way DCV (Normally Closed)
Figure shows a two-way two-position (normally closed) of spool type. A spool valve consists of a cylindrical
spool that slides back and forth inside the valve body to connect or block flow between the ports. The larger
diameter portion of the spool, the spool land blocks flow by covering the port. This particular valve has two
ports labeled P and A. P is connected to the pump line and A is connected to the outlet to the system. Figure
(left one) shows the valve in its normal state and its corresponding symbol. The valve is held in this position
by the force of the spring. In this position, the flow from the inlet port P is blocked from going to the outlet
port A. Figure (right one) shows the valve in its actuated state and its corresponding symbol. The valve is
shifted into this position by applying a force to overcome the resistance of the spring. In this position, the
flow is allowed to go to the outlet port.

Two-way–two-position normally closed DCV. Ports A and P are not connected when force is not
applied (valve unactuated) (Left). Ports A and P are connected when force is applied (valve actuated) (right).
2/2-Way DCV (Normally Opened)
igure 1.8 shows a two-way, two-position normally open DCV. The spring holds the valve in a position in
which ports P and Aare connected as shown in Fig. When the valve is actuated, the flow is blocked from
going to A as shown in Fig.

Two-way–two-position normally opened DCV. Ports A and P are connected when force is not applied (valve
unactuated) (Left). Ports A and P are not connected when force is applied (valve actuated) (right).

Application of 2/2 DCV

A pair of two-way valves is used to fill and drain a vessel. In Fig., valve 1 is shifted to the open position,
while valve 2 remains closed. This fills the vessel. In Fig.1.9(b), valve 2 is shifted to open position and valve
1 remains closed. This drains the vessel.
2/2-Way DCV (Normally Opened)

Fig. a Fig. b
3/2-Way DCV (Normally Closed)
Three-way valves either block or allow flow from an inlet to an outlet. They also allow the outlet to flow
back to the tank when the pump is blocked, while a two-way valve does not. A three-way valve has three
ports, namely, a pressure inlet (P),an outlet to the system(A)and a return to the tank(T). Figure shows the
operation of a 3/2-way valve normally closed. In its normal position, the valve is held in position by a spring
as shown in Fig. (a). In the normal position, the pressure port P is blocked and outlet A is connected to the
tank. In the actuated position shown in Fig. (b), the pressure port is connected to the tank and the tank port is
blocked.

Fig.(a)

3/2-way DCV (normally closed). Fig.(a) Ports A

and T are connected when force is not applied
(valve unactuated). Fig.(b) Ports A and P are
connected when force is applied (valve actuated).
Fig.(b)
3/2-Way DCV (Normally Opened)
Figure shows a three-way two-position DCV (normally open)with push button actuation and spring return. In the
normal position, shown in Fig. (a), the valve sends pressure to the outlet and blocks the tank port in the normal
position. In the actuated position, the pressure port is blocked and the outlet is vented to the tank.

Fig.(a) Fig.(b)
3/2-way DCV (normally opened). (a) Ports A and P are connected when force is not applied (valve unactuated).
(b) Ports A and T are connected when force is applied (valve actuated).

Application of 3/2 DCV for controlling a single-acting cylinder:

A 3/2 DCV is used to control a single-acting cylinder. Figure (a) shows the valve in its normal position in which
the pressure port is blocked and the outlet is returned to the tank. This allows the force of the to act on the piston
and retract the cylinder. The cylinder remains in the retracted position as long as the valve is in this position. In Fig.
(b), the valve position is shifted by the actuation of the push button. This connects the pressure port P with outlet A
and the tank port is blocked. This applies pump flow and pressure to the piston and the cylinder extends against the
light force of the spring.
 Fig.(a) Fig.(b)
Figure: Application of 3/2 valve–control of single-acting cylinder:(a) return; (b) extend

Application of 3/2 DCV for controlling a

double-acting cylinder: Double-acting
cylinders can be controlled with two 3/2-way
valves so arranged that when one valve
pressurizes one end of the cylinder, the other
valve exhausts the other end and vice versa
Figure :Application of 3/2 valve –controlling a double-acting cylinder
Four-Way Direction Control Valves
Four-way DCVs are capable of controlling double-acting cylinders and bidirectional motors. Figure shows the
operation of a typical 4/2 DCV. A four-way has four ports labeled P, T, A, and B. P is the pressure inlet and T is the
return to the tank; A and B are outlets to the system. In the normal position, pump flow is sent to outlet B. Outlet A
is connected to the tank. In the actuated position, the pump flow is sent to port A and port B connected to tank T. In
four-way DCVs, two flows of the fluids are controlled at the same time, while two-way and three-way DCVs
control only one flow at a time.
Application of 4/2-way valve to control a double-acting cylinder: A four-way DCV is used to control a double-
acting cylinder. When the valve is in the normal position, the pump line is connected to the end of the cylinder and
the blind end is connected to the tank as shown in Fig. (a). The cylinder retracts when the cylinder is in this
position. When the cylinder is fully retracted, the pump flow goes over to the pressure relief valve and back to the
tank. In Fig. (b), the pump line is connected to the blind end of the cylinder and the rod end is connected to the
tank. This causes the cylinder to extend. When the cylinder is fully extended, the pump flow again goes over the
pressure relief valve to the tank.

Application of a 4/2-way valve –

control of single-acting cylinder:
(a) return; (b) extend
The four-way, two-position DCVs used in the previous applications are sometimes impractical because they
continually send pump flow and pressure to the actuator in one direction or the other. Many cylinder and motor
applications require a third DCV position or neutral in which the actuator is subjected to pump pressure. Four-way
three-position circuits are therefore used in many hydraulic circuits.

Application of 4/3 DCV (closed neutral) for controlling a double-acting cylinder:

Solenoid-Actuated Valve
A spool-type DCV can be actuated using a solenoid. When the electric coil (solenoid) is energized, 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. Solenoids work against a push pin, which in turn actuates a spool.
There are two types of solenoid designs used to dissipate the heat developed in electric current flowing in the coil.
The first type dissipates the heat into surrounding air and is referred to as an “air gap solenoid.” In the second type
“wet pin solenoid,” the push pin contains an internal passage way that allows the tank port oil to communicate
between the housing of the valve and the housing of the solenoid. Wet pin solenoids do a better job in dissipating
heat because the cool oil represents a good heat sink to absorb heat from the solenoid. As the oil circulates, the
heat is carried into the hydraulic system where it can be easily dealt with.

Figure : Solenoid-Actuated Valve

 In the case of direct current (DC) solenoids, the current develops a magnetic field of fixed polarity. The DC
solenoids are practically safe from burning out if the correct voltage is applied. The solenoid force depends not
only on the solenoid design and current but also on the core position. The available commercial solenoids
produce a force of 60–70 N. For a greater force, the number of turns of coil or current should be increased.

Alternating current (AC) solenoids function in the same manner as DC solenoids but their magnetic fields are
influenced by the alternating current. The magnetic force is high when AC current is at its positive or negative
peak. As the current changes from positive to negative, it must pass through neutral points where there is no
current or no force. Due to this, load can push the core slightly out of equilibrium. This is commonly referred to
as buzz. To eliminate buzz, shading coils are used. A shading coil creates its own magnetic field but the current
produced lags behind the coil current and thus helps to prevent buzz.
A comparison between AC and DC solenoids is given in Table
Pilot-Operated Direction Control Valves
Pilot-operated DCVs are used in a hydraulic system operating at a high pressure. Due to the high pressure of the
system, the force required to actuate the DCV is high. In such systems, operation at a high pressure uses a small
DCV that is actuated by either a solenoid or manually. This pilot DCV in turn uses the pressure of the system to
actuate the main DCV
Piston Overlap
The switching characteristics of a valve are decided by the piston overlap. A distinction is made between the
positive, negative and zero overlap. Overlap is defined as the longitudinal difference between the length of land
and that of the port. The magnitude of overlap changes during unoperated and operated conditions.
The piston overlap determines the oil leakage rate. Overlapping is significant for all types of valve. The most
favorable overlap is selected in accordance with the application.

Figure : Valve overlap:

(a) Positive overlap; (b) negative overlap; (c) zero overlap
Classification of DCVs based on Design Characteristics
 An internal valve mechanism that directs the flow of fluid. Such a mechanism can either be a poppet, a
ball, a sliding spool, a rotary plug or a rotary disk.
 Number of switching positions (usually 2 or 3).
 Number of connecting ports or ways.
 Method of valve actuation that causes the valve mechanism to move into an alternate position.

The switching position, flow

direction, and port for
different configurations
2/2 way valve : 2ports and 2 position DCV

3/2 way valve : 3ports and 2 position DCV

4/2 way valve : 4ports and 2 position DCV

5/2 way valve : 5ports and 2 position DCV

4/3 way valve : 4ports and 3 position DCV

Actuating Devices
Direction control valves may be actuated by a variety of methods. Actuation is the method of moving
the valve element from one position to another. There are four basic methods of actuation: Manual,
mechanical, solenoid-operated and pilot-operated. Several combinations of actuation are possible using
these four basic methods.
 Manually operated: In manually operated DCVs, the spool is shifted manually by moving a handle
pushing or a button or stepping on a foot pedal. When the handle is not operated, the spool returns to
its original position by means of a spring.
 Mechanically operated: The spool is shifted by mechanical linkages such as cam and rollers.
 Solenoid operated: When an electric coil or a solenoid is energized, it creates a magnetic force that
pulls the armature into the coil. This causes the armature to push the spool of the valve.
 Pilot operated: A DCV can also be shifted by applying a pilot signal (either hydraulic or pneumatic)
against a piston at either end of the valve spool. When pilot pressure is introduced, it pushes the
piston to shift the spool.
Actuating Devices
Miscellaneous
Circuits

Figure : Raising and lowering large weights:

(a) Extend cylinder; (b) hold cylinder; (c) return cylinder
Miscellaneous Circuits

Figure : Use of shuttle valves to control single-acting cylinders: return (left) forward (right)
DCV Specifications
1. Valve Type:
Block and Bleed Valves : Block and bleed valves are configured so that flow through the valve is blocked at both
the inlet and outlet, and a small port is provided to drain or depressurize the space between. This configuration is
often required to isolate high-pressure sections of a system to facilitate safe maintenance or rapid depressurization.
These valves are also referred to as double block and bleed valves.
Cartridge / Manifold Valves : Cartridge valves are directional control valves that are inserted into manifolds to
provide a cost-effective, compact system design.
Check Valves : Check valves are self-activating safety valves that prevent process flow from reversing.
Control Valves : Control valves or proportional valves are power-operated devices used to modify fluid flow or
pressure rate in a process system.
Directional Valves : Directional valves direct or prevent flow through selected passages.
Diverter Valves : Diverter valves change the direction of the flow of a medium to two or more different
directions.
Drain Valves : Drain valves allow the removal of surplus fluid from a system or container.
Metering Valves : Metering valves are capable of accurately controlling the flow of a fluid.
Needle Valves : Needle valves have a slender, tapered point at the end of the valve stem that is lowered through
the seat to restrict or block flow. Fluid flowing through the valve turns 90 degrees and passes through an orifice
that is the seat for a rod with a cone shaped tip. These small valves are widely used to accurately regulate the flow
of liquids and gases at low flow rates. The fine threading of the stem and the large seat area allow for precise
resistance to flow. Advantages: Precise control. Disadvantages: low-pressure limitations, no slurries.
DCV Specifications
1. Valve Type:
Pressure Relief Valves : Pressure relief valves are self-actuated safety valves designed to relieve excess upstream
pressure from the line.
2. Valve Size : Valve size is the designated size of the valve by manufacturer. This typically represents the size of
the passage opening.
3. Pressure Rating : Maximum safe pressure value for which the valve is rated.
4. Number of Ports/Ways : Represents the number of connections or inlet / outlet ports to the valve.
5. Method of operation/Actuation : Manual, Mechanical Device, Electric, Pneumatic.

Material for DCVs (check from internet)

1. Valve body: It is made of carbon steel, ductile cast iron and stainless steel. Aluminum alloys are also preferred
for low-pressure applications. High-strength aluminum alloys are used for aircraft applications. Stainless steel is
used for corrosive environment. Sometimes plastics are also used for low-temperature applications.
2. Valve spool: It is made of hardened steel, ground and polished 15 Ni2Cr1Mo15 of hardness 60-62 HRC,
machined to 2–3 µm tolerance. Valve spool bore clearance is usually in the order of 5–10 µm.
Sample Question
 Explain briefly the function of DCVs.
 Draw a schematic of 4/2 DCV that is direct operated electrically and briefly explain its function.
 How are DCVs classified ?