Industrial Hydraulics and Pneumatics (IHP)

Unit-III
Control Valves

Valves-Construction, working, symbols and applications

of pressure control valves, Direction control valves, Flow
control valves
Dr. ANIL G. PATIL
Lecturer in Mechanical Engineering Department.
Government Polytechnic, Thane

2/17/2024 1
 Control Valves

Pneumatic and hydraulic systems require control

valves to direct and regulate the flow of fluid from
compressor or pump to the various load devices.

There are significant practical differences between

pneumatic and hydraulic devices (mainly arising from
differences in operating pressures and types of seals
needed for gas or liquid) the operating principles and
descriptions are very similar.
Pneumatic systems
Internal valve operation
 Valve control positions

Possible valve action for a 4/3 valve

Arrow-headed lines represent direction of flow.
For example fluid is delivered from port P to port A and returned
from port B to port T.

In pneumatic systems, lines commonly vent to atmosphere

directly at the valve, as shown by port R .
Hydraulic system Pneumatic system
There are three types of valves
1.Directional control valves (DCVs):
They determine the path through which a fluid transverses to a
given circuit.
2. Pressure control valves:
The function of a hydraulic pressure control valve is to regulate
the pressure of the fluid travelling through the pipe in a
hydraulic system. This is done by maintaining the required
pressure and keeping it at a safe level, whil releasing any excess
pressure that may cause pipes to leak or burst.
3. Flow control valves:
Hydraulic flow control valves are used to regulate speed within
a specific part of the hydraulic system to ensure optimum
performance at all times. By maintaining the flow rate and
pressure of the fluid, they directly regulate the speed of
motors and cylinders.
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.
DCV is mainly required for the following purposes:
1. To start, stop, accelerate, decelerate and change the direction
of motion of a hydraulic/Pneumatic actuator.
2. 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.
3. To vent the relief valve by either electrical or mechanical
control.
4. 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.
Classification of DCV
Directional valves control the way the air passes and are used
principally for controlling commencement, termination and
direction of air flow. The different classification scheme of the
pneumatic cylinders are given below
1. Based on construction 2. Based on the Number of ports
i) Poppet or seat valves i) Two way valves
- Ball seat valve ii) Three way valves
- Disc seat valve iii) Four way valves
- Diaphragm Valves 3. Based on methods of actuation
ii) Sliding spool valves i) Mechanical
- Longitudinal slide valve ii) Electrical
- Suspended spool valves iii) Pneumatic
- Rotary spool valves
4. Based on Size of the port
Size refers to a valve’s port size. The port sizes are designated as M5,
G1/8, and G1/4 etc. M refer to Metric thread, G refer to British
standard pipe (BSP) thread.
Port Markings of Direction Control Valve
Port designation of DCV
A. Ball seat valve.
In a poppet valve, discs, cones or balls are used to control flow.
If the push button is pressed, ball will lift off from its seat and allows the
air to flow from port P to port B.
When the push button is released, spring force and air pressure keeps
the ball back and closes air flow from port P to port B.

Two/Two (2/2) Ball seat Poppet valve

 Check valves
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 because it contains two ports.
Figure shows the graphical symbol of a check valve along with
its no-flow and free-flow directions.
 Ball-type check valve
 In Fig. a light spring holds the ball against the valve seat.
Flow coming into the inlet pushes the ball off the seat against the
light force of the spring and continues to the outlet.
 A very low pressure is required to hold the valve open in this
direction.
If the flow tries to enter from the opposite direction, the
pressure pushes the ball against the seat and the flow cannot pass
through.
B. Disc seat poppet valve
Figure shows the construction of a disc type 3/2 way DCV.
When push button is released, ports 1 and 3 are connected via hollow
pushbutton stem. If the push button is pressed, port 3 is first blocked by the
moving valve stem and then valve disc is pushed down so as to open the
valve thus connecting port 1 and 3.
 C. Poppet check valve
A poppet is a specially shaped plug element held on a valve seat
by a light spring.
Fluid flows through the valve in the space between the seat and
poppet.
In the free flow direction, the fluid pressure overcomes the
spring force. If the flow is attempted in the opposite direction,
the fluid pressure pushes the poppet in the closed position.
Therefore, no flow is permitted
Advantages of poppet valves are as follows
i) Response of poppet valve is very fast- short stroke to
provide maximum flow opening
ii) They give larger flow of valves for a small stroke
iii) The valve seats are usually simple elastic seals so wear is
minimum
iv) They are insensitive to dust and dirt and they are robust,
seats are self cleaning
v) Maintenance is easy and economical.
vi) They are inexpensive
vii) They give longer service life: short stroke and few wearing
parts give minimum wear and maximum life capabilities
Disadvantages of poppet valves are as follows
i) The actuating force is relatively high, as it is necessary to
overcome the force of the built in reset spring and the air
pressure.
ii) They are noisy if flow fluctuation is large.
Spool Direction Control Valves
A. Hand operated 3/2 DCV
The cross sectional views of 3/2 DCV (normally closed) based on
spool design is shown below. When the valve is not actuated, port 2
and 3 are connected and port 1 is blocked. When the valve is
actuated then port 2 and 1 are connected and port 3 is blocked.

3/2 Directional control valve (Normally closed)

B. Pneumatically actuated 3/2 DCV
The cross – sectional views of pneumatically actuated NC
type 3/2 DCV in normal position and actuated positions are
shown in the Figure
 C. Pneumatically actuated 4/2 DCV

The valve shown in Figure .

 is a 4/2 way valve pneumatically operated DCV. Switch over
is effected by direct application of pressure.
If compressed air is applied to pilot spool through control
port 12, it connects port 1 with 2 and 4 is exhausted through
port 3.
If the pilot pressure is applied to port 14, then 1 is connected
with 4 and line 2 exhausted through port 3.
 On disconnecting the compressed air from the control line,
the pilot spool remains in its current position until spool
receives a signal from the other control side.
Schematic diagram of 4/2 way valve
D. Suspended Disc Direction Control Valves

This valve is quite similar to 4/2 way spool valve. Schematic

diagram is shown in Figure

In this design disc is used instead of a spool.

This suspended disc can be moved by pilot pressure or by

solenoid or by mechanical means.

In this design, main disc connects port 1 to either port 4 or

2.

The secondary seat discs seal the exhaust port 3 whichever

is not functional. These values are generally provided with
manual override to manually move the cylinder.
4/2 Directional control valve (suspended disc type)
 Rotary valves

Rotary valves consist of a rotating spool which aligns with

holes in the valve casing to give the required operation.

Figure shows the construction and symbol of a typical valve

with centre off action.

Rotary valves are compact, simple and have low operating

forces.

They are, however, low pressure devices and are

consequently mainly used for hand operation in pneumatic
systems.
4/3 Rotary
valves
 Shuttle Valve (OR Gate)

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
Shuttle valve: (a) Flow from left to outlet and (b) flow from right to outlet
Quick/ Fast Exhaust Valve
Two Pressure Valve (And gate)

This valve is the pneumatic AND valve.

It is also derivate of Non Return Valve.
A two pressure valve requires two pressurised inputs to
allow an output from itself.
The cross sectional views of two pressure valve in two
positions are given in Figure.

As shown in the figure, this valve has two inputs 12 and 14

and one output 2. If the compressed air is applied to either
12 or input 14, the spool moves to block the flow, and no
signal appears at output 2. If signals are applied to both the
inputs 12 and 14, the compressed air flows through the
valve, and the signal appears at output 2.
Twin pressure valve symbol
 Time delay valve
Time delay valve function : In certain applications like machining
or press operation it is necessary that certain operation be
delayed by some fraction even after pressing valve.
Time delay valve function working:
Time delay valve is a combination valve .
The time delay can be increased or decreased by adjusting the flow
through the non-return flow control valve.
The change invariably increases or decreases the time taken to fill and
pilot actuates the direction control valve.
Time delay valve is a combination of a pneumatically actuated 3/2
direction control valve, an air reservoir and a throttle relief valve.
The time delay function is obtained by controlling the air flow rate to or
from the reservoir by using the throttle valve. Adjustment of throttle
valve permits fine control of time delay between minimum and
maximum times. In pneumatic time delay valves, typical time delays in
the range 5-30 seconds are possible.
Time delay Valve

Symbol
Methods of Actuation
 Pressure-control Valves
Pressure-control valves are used in hydraulic systems to control
actuator force (force = pressure × area) and to determine and select
pressure levels at which certain machine operations must occur.
Pressure controls are mainly used to perform the following system
functions:
1. Limiting maximum system pressure at a safe level.
2. Regulating/reducing pressure in certain portions of the circuit.
3. Unloading system pressure.
4. Assisting sequential operation of actuators in a circuit with
pressure control.
5. Any other pressure-related function by virtue of pressure
control.
6. Reducing or stepping down pressure levels from the main circuit
to a lower pressure in a sub-circuit.
The valves used for accomplishing the above-mentioned system
functions are therefore given the following names:
Types of Pressure control valve
1. Pressure-relief valve.
2. Pressure-reducing valve.
3. Unloading valve
4. Counterbalance valve.
5. Pressure-sequence valve.
6. Brake valve.
 Pressure-relief valve
 Pressure-relief valves limit the maximum pressure in a hydraulic
circuit by providing an alternate path for fluid flow when the
pressure reaches a preset level.
 All fixed-volume pump circuits require a relief valve to protect
the system from excess pressure. Fixed-volume pumps must
move fluid when they turn.
 When a pump unloads through an open-center circuit or
actuators are in motion, fluid movement is not a problem.
 A relief valve is essential when the actuators stall with the
directional valve still in shifted position .
 A relief valve is similar to a fuse in an electrical system.
 When circuit amperage stays below the fuse amperage, all is
well.
 When circuit amperage tries to exceed fuse amperage, the
fuse blows and disables the circuit.
 Both devices protect the system from excess pressure/current
by keeping it below a preset level.
 But electrical system requires maintenance.
In a hydraulic circuit, a relief valve opens and bypasses fluid
when pressure exceeds its setting.

 The valve then closes again when pressure falls.

This means that a relief valve can bypass fluid anytime, or all
the time, without intervention by maintenance.
Pressure-relief valve, Construction and symbol
If the hydraulic system does not accept any flow, then all the
pump flow must return to the tank via the relief valve.

The pressure-relief valve provides protection against any

overloads experienced by the actuators in the hydraulic system.

A relief valve is not needed if a pressure-compensated vane

pump is used.

Obviously one important function of a pressure-relief valve is to

limit the force or torque produced by hydraulic cylinders or
motors.
 Compound Pressure Relief Valve
(Pilot-Operated Pressure Relief Valve)
A pilot-operated pressure-relief valve consists of a small pilot
relief valve and main relief valve as shown in Fig.
It operates in a two-stage process:

1. The pilot relief valve opens when a preset maximum

pressure is reached.

2.When the pilot relief valve opens, it makes the main relief
valve open.
The pilot-operated pressure-relief valve has a pressure port that is
connected to the pump line and the tank port is connected to the
tank.
The pilot relief valve is a poppet type. The main relief valve
consists of a piston and a stem. The main relief piston has an
orifice drilled through it.
The piston has equal areas exposed to pressure on top and
bottom and is in a balanced condition due to equal force acting
on both the sides.
It remains stationary in the closed position. The piston has a
light bias spring to ensure that it stays closed. When the
pressure is less than that of relief valve setting, the pump flow
goes to the system.

If the pressure in the system becomes high enough, it moves

the pilot poppet off its seat. A small amount of flow begins to
go through the pilot line back to the tank. Once flow begins
through the piston orifice and pilot line, a pressure drop is
induced across the piston due to the restriction of the piston
orifice. This pressure drop then causes the piston and stem to
lift off their seats and the flow goes directly from the pressure
port to the tank.
The advantages of pilot-operated pressure-relief valves over
direct-acting pressure-relief valves are as follows:

1. Pilot-operated pressure-relief valves are usually smaller

than direct-acting pressure-relief valves for the same flow
and pressure settings.
2. They have a wider range for the maximum pressure
settings than direct-acting pressure-relief valves.
3. They can be operated using a remote while direct-acting
pressure-relief valves cannot.
 Pressure-Reducing Valve
This type of valve (which is normally open) is used to maintain
reduced pressures in specified locations of hydraulic systems. It
is actuated by downstream pressure and tends to close as this
pressure reaches the valve setting .
A pressure-reducing valve uses a spring-loaded spool to control
the downstream pressure. If the downstream pressure is below
the valve setting, the fluid flows freely from the inlet to the
outlet.
Note that there is an internal passageway from the outlet which
transmits outlet pressure to the spool end opposite the spring.
When the outlet (downstream) pressure increases to the valve
setting, the spool moves to the right to partially block the outlet
port.
Just enough flow is passed to the outlet to maintain its preset
pressure level. If the valve closes completely, leakage past the
spool causes downstream pressure to build up above the valve
setting. This is prevented from occurring because a continuous
bleed to the tank is permitted via a separate drain line to the
tank .
Reverse free flow through the valve is only possible if the
pressure exceeds the valve setting. The valve then closes, thus
making reverse flow impossible. Therefore, pressure-reducing
valves are often equipped with a check valve for reverse free
flow.
External forces acting onto a linear actuator increase the
pressure between the pressure-reducing valve and the
actuator.

In some systems, it is therefore desirable to relieve excess fluid

from the secondary system to the tank in order to maintain a
constant downstream pressure, regardless of such external
forces .

A reducing valve is normally open. It reads the downstream

pressure. It has an external drain.
This is represented by a line connected from the valve drain
port to the tank.

The symbol shows that the spring cavity has a drain to the
tank.
Pressure-Reducing Valve
Application of a pressure-reducing valve
 Counterbalan
ce Valve
Schematic diagram of counterbalance valve is shown in Fig.
These normally closed valves are primarily used to
maintain a back pressure on a vertical cylinder to prevent it
from falling due to gravity.

They are used to prevent a load from accelerating

uncontrollably. This situation can occur in vertical cylinders
in which the load is a weight. This can damage the load or
even the cylinder itself when the load is stopped quickly at
the end of the travel.
Valve’s primary port is connected to the cylinder’s rod end
and the secondary port to the directional control valve.

The pressure setting is slightly higher than that required to

keep the load from free-falling.
When the pressurized fluid flows to the cylinder’s cap end,
the cylinder extends, increasing pressure in the rod end and
shifting the main spool in the counterbalance valve.

This creates a path that permits the fluid to flow through the
secondary port via the directional control valve and to the
reservoir.

As the load is raised, the integral check valve opens to allow
the cylinder to retract freely.
Counterbalance Valve
Application of a counterbalance valve
Counterbalance valves are commonly used to counterbalance
a weight or external force or counteract a weight such as a
platen or a press and keep it from freefalling.

Figure illustrates the use of a counterbalance or back-

pressure valve to keep a vertically mounted cylinder in the
upward position while the pump idles, that is, when the DCV
is in its centre position.

During the downward movement of the cylinder, the

counterbalance valve is set to open at slightly above the
pressure required to hold the piston up (a check valve does
not permit flow in this direction).
The control signal for the counterbalance valve can be
obtained from the blank end or rod end of the cylinder.
 Pressure Sequence Valve
A sequence valve is a pressure-control valve that is used to
force two actuators to operate in sequence. They are similar
to pressure-relief valves. Schematic diagram of sequence
valve is shown in Fig. 1.18.
Instead of sending flow back to the tank, a sequence valve
allows flow to a branch circuit, when a preset pressure is
reached. The check valve allows the sequence valve to be
bypassed in the reverse direction. The component enclosure
line indicates that the check valve is an integral part of the
component. The sequence valve has an external drain line;
therefore, a line must be connected from the sequence
valve’s drain port to the tank.
The symbol for a sequence valve is shown in Fig.
Sequence valve
Symbol of Sequence valve
Application of a sequence valve.
 Unloading Valves
Unloading valves are pressure-control devices that are used
to dump excess fluid to the tank at little or no pressure.
A common application is in high-low pump circuits where
two pumps move an actuator at a high speed and low
pressure.
The circuit then shifts to a single pump providing a high
pressure to perform work In a pilot-operated unloading
valve; the unloading spool receives a signal through the
remote-pilot port when pressure in the working circuit goes
above its setting. At the same time, pressure on the spring-
loaded ball in the pilot section starts to open it. Pressure
drop on the front side of the unloading spool lowers back
force and pilot pressure from the high-pressure circuit
forces the spring-loaded ball completely off its seat. Now
there is more flow going to the tank than what the control
orifice can keep up with.
Application of unloading valve in a punching press
(high–low circuit).
 FLOW-CONTROL VALVES
Flow-control valves, as the name suggests, control the
rate of flow of a fluid through a hydraulic circuit.
Flow-control valves accurately limit the fluid volume rate
from fixed displacement pump to or from branch circuits.
Their function is to provide velocity control of linear
actuators, or speed control of rotary actuators .

Factors that determine the flow rate (Flow-Control Valves

factors)
1. Cross-sectional area of orifice.
2. Shape of the orifice (round, square or triangular).
3. Length of the restriction.
4. Pressure difference across the orifice (Δp).
5. Viscosity of the fluid.
 Functions of Flow-Control Valves
Flow-controlvalves have several functions, some of which are
listed below:
1.Regulate the speed of linear and rotary actuators:They
control the speed of piston that is dependent on the flow rate
and area of the piston:
Velocity of piston (Vp) (m/s) = Flow rate in the actuator/Piston
=Q/A
2. Regulate the power available to the sub-circuits by
controlling the flow to them:
Power (W) = Flow rate ×Pressure (P = Q×p )
3.Proportionally divide or regulate the pump flow to various
branches of the circuit: It transfers the power developed by
the main pump to different sectors of the circuit to manage
multiple tasks, if necessary.
Non-pressure-compensated flow-control valves
These used when the system pressure is relatively constant
and motoring speeds are not too critical. The operating
principle behind these valves is that the flow through an orifice
remains constant if the pressure drop across it remains the
same. In other words, the rate of flow through an orifice
depends on the pressure drop across it.
The disadvantage of these valves is discussed below. The inlet
pressure is the pressure from the pump that remains constant.
Therefore, the variation in pressure occurs at the outlet that is
defined by the work load. This implies that the flow rate
depends on the work load. Hence, the speed of the piston
cannot be defined accurately using non-pressure-compensated
flow-control valves when the working load varies. This is an
extremely important problem to be addressed in hydraulic
circuits where the load and pressure vary constantly.
 Non-pressure-compensated flow-
control valves

Non-pressure-compensated needle-type flow-control

valve. (a) Fully closed; (b) partially opened; (c) fully
opened
Flow-control valve with an integrated check valve.
 Pressure-Compensated Valves
Pressure-compensated flow-control valves overcome the
difficulty caused by non-pressure-compensated valves by
changing the size of the orifice in relation to the changes in the
system pressure.
This is accomplished through a spring-loaded compensator
spool that reduces the size of the orifice when pressure drop
increases.
Once the valve is set, the pressure compensator acts to keep
the pressure drop nearly constant.
It works on a kind of feedback mechanism from the outlet
pressure. This keeps the flow through the orifice nearly
constant.
Pressure-Compensated flow control
Valves
A pressure-compensated flow-control valve consists of a main
spool and a compensator spool. The adjustment knob controls
the main spool’s position, which controls the orifice size at the
outlet.
The upstream pressure is delivered to the valve by the pilot
line A. Similarly, the downstream pressure is ported to the right
side of the compensator spool through the pilot line B.
The compensator spring biases the spool so that it tends
toward the fully open position. If the pressure drop across the
valve increases, that is, the upstream pressure increases
relative to the downstream pressure, the compensator spool
moves to the right against the force of the spring. This reduces
the flow that in turn reduces the pressure drop and tries to
attain an equilibrium position as far as the flow is concerned.
In the static condition, the hydraulic forces hold the
compensator spool in balance, but the bias spring forces it to
the far right, thus holding the compensator orifice fully open.
In the flow condition, any pressure drop less than the bias
spring force does not affect the fully open compensator
orifice, but any pressure drop greater than the bias spring
force reduces the compensator orifice.
Any change in pressure on either side of the control orifice,
without a corresponding pressure change on the opposite
side of the control orifice, moves the compensator spool.
Thus, a fixed differential across the control orifice is
maintained at all times. It blocks all flow in excess of the
throttle setting. As a result, flow exceeding the preset
amount can be used by other parts of the circuit or return to
the tank via a pressure-relief valve.
 Other Valves
Servo valves, Modular valves and
Cartridge valves
 Servo valves
Servo valves are a close relative of the proportional valve and are based
on an electrical torque motor which produces a small deflection
proportional to the electrical current through its coil.
They commonly use feedback between the main and pilot spools to
give precise control.

A typical device is shown in Figure. This consists of a small pilot spool

connected directly to the torque motor. The pilot spool moves within a
sliding sleeve, mechanically linked to the main spool.
Figure illustrates the construction of a different type of servo valve,
called a jet pipe servo. Pilot pressure is applied to a jet pipe which, with
a 50% control signal, directs an equal flow into two pilot lines. A change
of control signal diverts the jet flow, giving unequal flows and hence
unequal pressures at ends of the main spool. The main spool is linked
mechanically to the jet pipe, causing it to move to counteract the
applied electrical signal. Spool movement ceases when the jet pipe is
again centrally located over the two pilot pipes. This occurs when the