Presentation

on
Direction & Pressure
Control Valves
Presented
By

Mr.Patil Gopal Bhaskar

Department of Mechanical Engineering

K.E.Society’s Rajarambapu Institute of
Technology(Polytechnic),Pune
Valves:
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”.
1. Directional control valves:
They determine the path through
which a fluid transverses a given circuit.
These valves are used to control the start,
stop and change in direction of flow of
pressurized fluid.
2.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.
3.Flow control valves:
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.
Directional control valves can be classified in a number of ways:
1. According to type of construction :
(a). Poppet valves
(b).Spool valves
2. According to number of working ports :
(a).Two- way valves
(b).Three – way valves
(c).Four- way valves.
3. According to number of Switching position:
(a) .Two – position
(b).Three - position
4. According to Actuating mechanism:
(a)Manual actuation
(b) Mechanical actuation
(c) Solenoid ( Electrical ) actuation
(d) Hydraulic ( Pilot ) actuation
(e) Pneumatic actuation
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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.

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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. 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.

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Rotary spool type:
In this type, the spool is rotated to
change the direction of fluid. It has
longitudinal grooves. The rotary spools are
usually manually operated. The figure shows
a 3/2 rotary spool valve. It has rotary spool
inside the valve body. The spool is rotated
through 120 to operate the valve.
In spool position as shown in figure,
there is connection from P to A. Fluid flows
from pump to single acting cylinder.
Hence the cylinder extends. The tank
port or exhaust port, that is, port-T is closed.
When the spool is turned to 120,that
is, as shown in figure, there is connection
from port-A to port-T. Fluid flows from
single acting cylinder to tank. Hence the
cylinder retracts. The inlet port port-P is
closed.
2. According to number of working ports :
(a).Two- way valves:
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. Figure 4.7 above 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. T
These ports are generally identified as follows :
P= pressure( Pump)port
A or B = working port
T = tank port.
Figure (a) and (b) shows the two position of the three –
way valve actuated manually by a push button.
a . 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.

Spring
b . Spool position 2:
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 b).
3. 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. Four-way valve comes
with two or three position.
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 .

Valve body
b.) Closed Center 3 / 4 DCV :
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. 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 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.

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 d.) Regenerative Center 3 / 4 DCV :
Regenerative means the flow generated from the
system itself. Regenerative center is used whenever the
actuator movement in one direction requires two different
speeds e.g. 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 center saves on additional
pump capacity required.

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Fig .shows double acting single rod cylinder connected to 3 / 4 DCV
having regenerative center. The piston area(A) is more than ring area (B) .
When the cylinder is 1 0 2 actuated by this type of DCV , in the center
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.
4. According to Actuating mechanism:

1. Manually – actuated Valve:

A 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

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 deactivated.
3. Solenoid-actuated DCV :
A very common way to actuate a spool valve is by
using a solenoid is illustrated in Fig. 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.
4.Hydraulic actuation:
This type actuation is usually known as pilot- actuated valve. The
hydraulic pressure may directly used on the end face of the spool . The pilot
ports are located on the valve ends. Fig 4.19a. 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. Fig 4.19b. shows the
symbol of 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 un shaded arrow represent
pneumatic signal .
2.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. 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.

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.
1.Pressure Relief 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).

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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.
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2. Unloading Valve:
A unloading valve is used to permit a pump to operate at minimum
load. The unloading valve is normally closed valve with the spool
closing the tank port. It operates on the principle that pump
delivery is diverted to the tank, when sufficient pilot pressure is
applied to move the spool against the spring force. The valve is
held open by pilot pressure until the pump delivery is again needed
by the circuit. The pilot fluid applied to move the spool upwards
becomes a static system. In other words, it merely pushes the spool
upward and maintains a static pressure to hold it open. When the
pilot pressure is relaxed, the spool is moved down by the spring,
and flow is diverted through the valve into the circuit. The spool
type unloading valve is shown in fig 4.28. The valve consists of a
spring chamber ( control chamber ) with an adjustable bias spring
which pushes the spool closing the tank port. The valve has 2 ports
one connecting the pump and other connecting the tank. The
movement of the spool inside the bore opens or closes the ports.
Drain is provided to remove the oil that may collect in control
chamber due to leakage, thereby preventing valve failure
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3. Sequence valve:
A sequence valve’s primary function is to divert flow in a
predetermined sequence. It is a pressure- actuated valve similar in construction
to a relief valve and normally a closed valve. The sequence valve operates on
the principle that when main system pressure overcomes the spring setting, the
valve spool moves up allowing flow from the secondary port. A sequence
valve may be direct or remote pilot- operated. These valves are used to control
the operational cycle of a machine automatically. Sequence valve may be
directly operated as shown in the fig 4.29b. The valve consists of a spring
chamber ( control chamber ) with an adjustable bias spring for setting the
pressure. It consists of 2 ports, one main port connecting the main line and
other (secondary port) connected to the secondary circuit. Usually the
secondary port is closed by the spool. 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. The pressure is effective on
the end of the spool. This pressure will urge the spool against the spring force
and at the preset value of the spring it allows a passage from the primary to the
secondary port. For remote operation it is necessary to close the passage used
for direct operation by plugging and provide a separate pressure source as
required for the operation of the spool in the remote operation mode.
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4. Counterbalance Valve:
A Counterbalance valve is used to maintain back pressure to
prevent a load from failing. One can find application in vertical
presses, lift trucks, loaders and other machine tool that must position
or hold suspended loads.
The valve consists of a spring chamber ( control chamber )
with an adjustable bias spring which controls the movement of spool.
It has two ports, one connected to load and the other to the tank 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. Counterbalance valve acts on the principle that
fluid is trapped under pressure until pilot pressure, either direct or
remote(only one opened at a time and other blocked ), has to
overcomes the spring force setting in the valve. Fluid is then allowed
to escape, letting the load to descend under control. This valve can be
used as a “braking valve” for decelerating heavy inertia load.
A counterbalance valve is normally closed valve and will
remain closed until acted upon by a remote pilot pressure source.
Therefore, a much lower spring force is sufficient to allow the valve
to operate at a lesser pilot pressure.
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 When a counterbalance valve is used on large vertical presses, it may
important to analyze the source of pilot pressure. Figure 4.31 (a) and (b) illustrate
the comparison between direct and remote pilot signal
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.

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 Pressure Reducing Valve
Its main function is to reduce the pressure in particular
branch of the circuit to different level as demanded by
consumers in branch.
In normal position, port 'P' is supplying oil to consumer
port 'A'. If the main supply pressure is below the set
pressure, there will be continuous flow from P -> A.
Hence, normally valve is open.
When outlet pressure rises to valve setting,
then oil flow through passage 'X' & will act on spool &
spool will shift to right thereby partly closing the port
'A'. Now only enough flow will pass through port 'A' so
consumer connected to 'A' will receive reduced pressure.
Flow control Valve Functions:
1.Regulation of fluid flow rate of
actuators
2.Speed control of actuator
3.Control of power output from actuators
4.Distribution of available flow from the
pump to various branches of hydraulic
circuit
Needle type flow control Valve:
A needle valve has a pointed needle that can be
adjusted upward or downward by rotating the hand
wheel. Since we can accurately control the needle,
which in turn controls the outflow.
This valve is also used as a “stop valve” to stop or
“shut-off” the flow.
Pressure compensated flow control Valve:
Pressure compensated flow control Valve:
In any hydraulic circuit, pressure changes, the rate of
flow changes. But many circuits require constant flow
regardless of input or output pressure variation in the circuit.
Then we must use a pressure-compensated flow control valve.
When pressurized oil entering through the inlet port
will apply full force on the bottom of the poppet and will try
to compress the spring, by shifting the poppet to the right. The
poppet will move to the right till the spring force and the
pressure force acting on the poppet balance each other.
Therefore, when pressurized oil entering through the inlet port
will apply full force on the bottom of the poppet and will try
to compress the spring, by shifting the poppet to the right. The
poppet will move to the right till the spring force and the
pressure force acting on the poppet balance each other.