Module-2 18MT54 - Hydraulics and Pneumatics

Control components in Hydraulic system

Introduction
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.

• Directional control valves

• Pressure control valves
• 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.

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

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
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.

Figure- 2/2 valve symbol

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

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

Figure- 2/3 valve symbol

A valve with 4 service ports and 2 position is designated as 2 / 4 valve.

Figure- 2/4 valve symbol

A valve with 4 Service ports and 3 Switching position is designated as 3 / 4 way valve.
Below Figure shows an example of open cantered position.

Figure- 3/4 valve symbol

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

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

Poppet Valves:
Directional poppet valves consist 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
Advantages 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).

1. 2 / 2 DCV (Poppet design)

Figure- 2 / 2 DCV (Poppet design)

The above Figure 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 is shown in below figure.

Figure- Symbol of 2/2 poppet valve (Check valve)

Department of Mechatronics NAVEEN KUMAR S N
Module-2 18MT54 - Hydraulics and Pneumatics

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):

Figure- 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 designs are also available. The above

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

figure shows Spool type 2 / 2 DCV manually actuated. In Fig 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. The Below figure (a) and (b) shows the two position of the three – way valve actuated
manually by a push button.

Figure- 2 /3 DCV

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

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.

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).
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.
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 centred 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 centre 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.

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

Three- position, four- way DCV have different variety of centre configurations. The
common varieties are the open centre, closed centre, tandem centre, floating centre, &
regenerative centre with open, closed and tandem are the three basic types A variety of centre
configurations provides greater flexibility for circuit design.
a.) Open centred 3 / 4 DCV: In open- centre circuit, all ports are open to each other in the
centre position. When the valve is in open centre 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 centre valve help to prevent heat build up, and no work can be done by
any part of the system, as long as the valve remains in the centre 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.
The Below Figures a,b,c. shows the three positions of 3 / 4 DCV. Fig a. shows the valve
is mid position i.e when the valve is deactuvated. In fig 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 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.

Figure- 3 position- 4 way, open centered DCV

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

Figure- Symbol of 3 position- 4 way, open centered DCV

b.) Closed Centred 3 / 4 DCV:

Figure- Construction and Symbol of 3 position- 4 way, Closed centre DCV

The Above Figure shows a closed centre 3- position, 4 – Way DCV in its centre
position. The working of the valve is similar to open centre DCV and in actuated position the
port connection is identical. In closed centre 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 build up in the system.
This promotes oil oxidation, viscosity drop, which further raises the wear of parts and increased
leakage. With this type of centre 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 –centre
versions are used only when multiple circuit or functions must be accomplished in the system
from one power source.

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

c.) Tandem centred 3 /4 DCV: The Below Figure shows a tandem centre 3-position, 4-way
DCV. In the centre configuration, the working ports A and B are blocked, and the pump port P
is connected to tank port T. The tandem canter 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 circuitries.

Figure- Construction and Symbol of 3 position- 4 way, Tandem centre DCV

d.) Regenerative Centre 3 / 4 DCV: This is another type of common centre configuration used
in hydraulic circuits. Regenerative means the flow generated from the system itself.
Regenerative centre 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 centre saves
on additional pump capacity required.
The Below Figure shows double acting single rod cylinder connected to 3 / 4 DCV
having regenerative centre. The piston area(A) is more than ring area (B). When the cylinder
is actuated by this type of DCV, in the centre 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

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

Figure- Double acting cylinder connected to Regenerative centre 3 /4 DCV

d.) Regenerative Centre 3 / 4 DCV: The Below Figure shows floating centre 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 centre, 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 builds up heat in the circuit.
Hence this centre configuration is used only in special case.

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

Figure- Construction and Symbol of 3 position- 4 way, Regenerative centre DCV

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. Below Figures a and b shows
the two position of 2 / 4 DCV.

Figure- Construction and Symbol of 2/4 DCV

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

Actuation of Directional control valves

Directional control valves can be actuated by different methods.
Manually – actuated Valve: 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

The above figure shows the symbol of 2 / 4 DCV with manually operated by roller
tappet to1 and spring return to 2. And 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.
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 centre configuration when deactuated.
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 within its less
switching time.

Figure- Solenoid Actuation of DCV

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

The above Figure shows the working of a solenoid actuated valve when left coil is
energized, it 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 coils are de-energized the spool will come
to the mid position by spring force. Below Figure a shows 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.

Figure- Solenoid Actuated DCV

Hydraulic actuation
This type actuation is usually known as pilot- actuated valve. The hydraulic pressure
may be directly used on the end face of the spool. The pilot ports are located on the valve ends.
The below Figure a. 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. The below Figure b. shows
the symbol of pilot actuated 2 / 4 DCV.

Figure- Construction and Symbol of Pilot (Hydraulic) Actuation

Department of Mechatronics NAVEEN KUMAR S N

Module-2 18MT54 - Hydraulics and Pneumatics

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. Below Figure shows the symbol for pneumatic actuated 2 / 4 DCV.

Figure: Symbol of Pneumatic 2/4 DCV

Department of Mechatronics NAVEEN KUMAR S N