Fluid Mechanics-II (ME-221)

Teacher/Instructor: Engr. Muhammad Sumair

B.Sc. Mechanical Engineering (UET Lahore 2014-2018)

M.Sc. Thermal Power Engineering (UET Lahore 2018-2020)
Control Components in Hydraulic Systems
• One of the most important considerations in any fluid power system is
control. If control components are not properly selected, the entire
system will not function as required. Fluid power is controlled
primarily using control devices called valves. There are three basic
types of control devices: (1) directional control valves, (2) pressure
control valves, and (3) flow control valves.
• Directional Control Valves (DCVs) determine the path through
which a fluid traverses within a given circuit. For example, they
establish the direction of motion of a hydraulic cylinder or motor. This
control of the fluid path is accomplished primarily by check valves,
two-way, three-way, and four-way directional control valves.
 Control Components in Hydraulic Systems
(Cont’d)
• Pressure Control Valves (PCVs) protect the system against
overpressure. For example, in applications where precise control of
hydraulic cylinder or motor speed is required, pressure reducing valves
ensure that the pressure supplied to the actuator remains within
specified limits.
• Flow Control Valves (FCVs) are essential components in hydraulic
systems that regulate the speed or flow rate of hydraulic fluid through
a specific section of the system. These valves are crucial for
controlling the movement of hydraulic actuators, and ensuring the
efficiency of various hydraulic applications. In hydraulic systems with
cylinders, flow control valves regulate the speed of cylinder extension
and retraction. Similarly, flow control valves are used to regulate the
speed of hydraulic motors.
 Directional Control Valves (DCVs)
• As the name implies, DCVs are used to control the direction of flow in
a hydraulic circuit. The simplest type is a check valve (Fig. 1), which
is also called non-return valve or one-way valve because it permits
free flow in one direction and prevents any flow in the opposite
direction.
• Fig. 2 shows the internal operation of a check valve. As shown, a light
spring holds the poppet in the closed position. In the free-flow
direction, the fluid pressure overcomes the spring force at about 5 psi.
If flow is attempted in the opposite direction, the fluid pressure pushes
the poppet (along with the spring force) in the closed position.
Therefore, no flow is permitted. The higher the pressure, the greater
will be the force pushing the poppet against its seat.
 DCVs (Cont’d)
• Thus, increased pressure will not result in any tendency to allow flow
in the no-flow direction.

Figure 1: A Typical Check Valve

Figure 2: Operation of
Check Valve
 DCVs (Cont’d)
• Figure 3 shows the free flow direction implied when using the
symbolic representation of a check valve. This symbol, which clearly
shows the function of a check valve, will be used when drawing
hydraulic circuits. Note that a check valve is analogous to a diode in
electric circuits.

Figure 3: Symbol for a check valve with its

free-flow direction defined.
 DCVs (Cont’d)
• Additional types of DCVs are the 2/2, 3/2, 4/2, and 4/3 valves used to direct
inlet flow to either of two outlet ports. This first digit indicates the number
of ports, and the second digit indicates the number of positions. Ports are
shown through alphabets. Various symbols used for the ports are P (for
pressure port), T or R (Tank port or Return port to the reservoir), A and B
(the working ports or the cylinder ports). As an example, see the Fig. 5.
• Hydraulic DCVs use a sliding spool to change the path of flow through the
valve. For a given position of the spool, a unique flow path configuration
exists within the valve. DCVs are designed to operate with either two
positions of the spool or three positions of the spool. The flow path
configuration for each unique spool position is shown symbolically by a
rectangle, sometimes called an envelope.
 DCVs (Cont’d)

Figure 4: Two-way and four-way directional

control valves
 DCVs (Cont’d)
• 2/2 DCV: According to the nomenclature discussed earlier, this valve
has two ports (P and A) and two positions, as shown below:

Figure 5: 2/2 DCV

 DCVs (Cont’d)
1) Position 1 (P is connected to A): In this position, the spool is located
in the valve such that the port P and A are get connected and oil can
easily flow from P to A. This position starts the oil supply to the system.
2) Position 2 (P is not connected to A): In this position of D.C. valve,
the spool is shifted toward right envelop so that the port P is closed and
thus, port P and A are disconnected. The oil will not flow from P to A.
This position stops the oil supply to the system.
• 3/2 DCV: According to the nomenclature discussed earlier, this valve
has three ports (P, A and R) and two positions, as shown next:
 DCVs (Cont’d)

Figure 6: 3/2 DCV

1)Position 1:In this position, the port P and port A is get connected and
R port is closed. It will supply the oil to the actuator while flow to the
tank port is blocked.
2)Position 2: When spool is shifted, it will block the port P of the pump
to stop the supply of pressurized oil to the system. The port A and port R
get connected so that oil will drain to the reservoir.
 DCVs (Cont’d)
• 4/2 DCV: According to the nomenclature discussed earlier, this valve
has four ports (P, A, B, and R) and two positions, as shown below:

Figure 7: 4/2 DCV

 DCVs (Cont’d)
1)Position 1: In this position of D.C. Valve, the spool is placed such
that the pump port P get connected to the port A of actuator and port B
of actuator is connected to the reservoir port R to drain out the oil
2)Position 2: In this position, the spool is shifted with the help of push
button and spring. Now the port P is connected port B of actuator and
port A of actuator is connected to the reservoir port R to drain out the
oil.
• This valve is typically used to operate double acting hydraulic cylinder
or bi-directional hydraulic motor.
 DCVs (Cont’d)
• 4/3 DCV: According to the nomenclature discussed earlier, this valve
has four ports (P, A, B, and R) and three positions as shown below:

Figure 8: 4/3 DCV

 DCVs (Cont’d)
1)Position 1: It is similar to 4/2 D.C. valve. It connects P to A, B to R
2)Position 2: It is normal position shown in fig. In this position, the
spool is shifted such that port P is closed and oil will not flow from it to
the port A or port B. Similarly, there is no oil path from port A or B to
the reservoir port. It means that all ports of the valves are closed or
blocked off. This position called as closed centre position. There are
different types of mid positions as explained next.
3)Position 3: It is similar to 4/2 D.C Valve in which connections are A
to R, P to B
• It is used to actuate double acting cylinder/Bi-directional hydraulic
motor with intermediate stoppage of the cylinder or motor.
 DCVs (Cont’d)
Types of Central (Mid) Position: In 4/3 DCV, there are three positions
and 1st and 3rd are same as for 4/2 DCV/ However, there is an additional
mis position in 4/3 DCV. This mis position can have different
possibilities which are discussed next:
1) Open Center: This means that all four ports are interconnected
(often used in hydraulic motors) with each other as shown below:
 DCVs (Cont’d)
2) Closed Center: This means that all four ports are blocked.

3) Tandem Center: In this position, P and T (R) ports are connected but
actuator is blocked i.e. no supply to A and B ports.
 DCVs (Cont’d)
4) Regenerative Center: This means that port P is connected to both A
and B, but T (R) is blocked.

5) Float Center: In this position, P is blocked, and A & B are connected

to T (R) port. It is used to drain out the actuator.
 Sealing Devices
• Oil leakage, located anywhere in a hydraulic system, reduces efficiency and
increases power losses. Internal leakage does not result in loss of fluid
from the system because the fluid returns to the reservoir. Most hydraulic
components possess clearances that permit a small amount of internal
leakage. This leakage increases as component clearances between mating
parts increase due to wear. If the entire system leakage becomes large
enough, most of the pump's output is bypassed, and the actuators will not
operate properly.
• External leakage represents a loss of fluid from the system. In addition, it
might represent a safety hazard. Improperly assembled pipe fittings is the
most common cause of external leakage. Overtightened fittings may
become damaged, or vibration can cause properly tightened fittings to
become loose. Shaft seals on pumps and cylinders may become damaged
due to misalignment or excessive pressure.
 Sealing Devices (Cont’d)
• Seals are used in hydraulic systems to prevent excessive internal and
external leakage and to keep out contamination. Seals can be of the
positive or non-positive type and can be designed for static or dynamic
applications.
• Positive seals do not allow any leakage whatsoever (external or
internal). Non-positive seals (such as the clearance used to provide a
lubricating film between a valve spool and its housing bore) permit a
small amount of internal leakage.
• Static seals are used between mating parts that do not move relative to
each other. Figure 9 shows some typical examples which include
flange gaskets and seals. Notice that these seals are compressed
between two rigidly connected parts. They represent a relatively
simple and non-wearing joint, which should be trouble-free if properly
assembled.
Sealing Devices (Cont’d)

Figure 9: Static seal flange applications

 Sealing Devices (Cont’d)
• Dynamic seals are assembled between mating parts that move relative
to each other. Hence, dynamic seals are subject to wear because one of
the mating parts rubs against the seal.
• The following represent the most widely used types of seal
configurations:
1. O-rings
2. Compression packings (V- and U-shapes)
3. Piston cup packings
4. Piston rings
5. Wiper rings
 Sealing Devices (Cont’d)
• The O-ring is one of the most widely used seals for hydraulic systems.
It is a molded, synthetic rubber seal that has a round cross section in
its free state. See Fig. 10 for several different-sized O-rings, which can
be used for most static and dynamic conditions. These O-ring seals
give effective sealing through a wide range of pressures, temperatures,
and movements.

Figure 10: Different sized O-rings

 Sealing Devices (Cont’d)
• As illustrated in Fig. 11, an O-ring is installed in an annular groove
machined into one of the mating parts. When pressure is applied, the
O-ring is forced against a third surface to create a positive seal. As a
result, the O-ring is capable of sealing against high pressures.
• However, O-rings are not generally suited for sealing rotating shafts or
where vibration is a problem. At very high pressures, the O-ring may
extrude into the clearance space between mating parts, as illustrated in
Fig. 12. This is unacceptable in dynamic application because of the
rapid resulting seal wear. This extrusion is prevented by installing a
backup ring, as shown in Fig. 12. If the pressure is applied in both
directions, a backup ring must be installed on both sides of the O-ring.
 Sealing Devices (Cont’d)

Figure 11: O-ring operation

 Sealing Devices (Cont’d)

Figure 12: Back-up ring for prevention

of extrusion
Thanks for Listening