UNIT-3

Control Components in Hydraulic Systems

Control components(Valves): For proper functioning of a hydraulic
system control components are essential.
Valves are used to control direction, pressure and flowrate of fluid flow.

Classification of control valves:

1. Direction control valves(DCV)
2. Pressure control valves(PCV)
3. Flow control valves(FCV)
1. Direction control valves(DCV):
Direction control valves are used to start, stop and control the direction of
flow in a hydraulic circuit.
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 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 pumps 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.
Classification of Direction control valves:
Direction control valves are classified based on many factors, they are
A. Based on construction
a. Ball Check valves
b. Poppet or Seat valves
c. Spool valves
d. Shuttle valves.

B. Based on number of ports or flow paths:

a. Two-way valves
b. Three-way valves
c. Four way valves.
C. Based on mode of actuation:
a. Manually operated(actuated) valve
b. Mechanically operated valve
c. Solenoid operated valve
d. Pilot operated valve.
A. Based on construction:
a. Ball Check valves: It is simplest type of DCV, A check valve allows
flow in one direction but blocks the flow in opposite direction
(Unidirectional valves). It is 2-way valve because it contains 2 ports.
Graphical symbol of Check valve is
In this valve a light spring holds the ball
against the valve seat. Flow coming in to
the inlet pushes off the seat against the
force of the spring and continues to the
outlet. A very low pressure is required to
keep 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.
Functions:
b. Poppet valves:
c. Spool valves:
Spool valves may be either sliding type or rotary type.
Sliding type spool valve consists of a spool, inside a valve casing.
Opening and closing of the ports is provided in the casing by actuating
the spool by an external force.
Rotary type spool valve consists of a spool, inside a valve casing.
Opening and closing of the ports is provided in the casing by actuating
the spool by an external force.
Difference between Poppet valves and Spool valves:

Poppet Valves Spool Valves

1. They have larger internal surface area They have smaller internal surface area
and higher flow rate and lower flow rate

2. Poppet valves are Unbalanced Spool valves are Balanced

3. Higher actuating force is required due Lower actuating forces are required
to spring

4. Seal wear is less Seal wear is more

5. They are inexpensive They are expensive
B. Based on number of ports or flow paths:
Two-,Three- and Four-way valves. They are also called two-,three- and
four-port valves and
These valves are characterised by the number of ports present in the
valve and position.
Port: It indicates openings on the valve body for interconnections
between the pump, systems and tank.
Name of ports:
P- Port to pump
A- Port to system
B- Port to system
T- Port to tank
Position: It indicates the position of the internal valving element(such
as spool) that can occupy when actuated.
Eg: m/n valve, m always refers to the number of ports.
a. 2-way valve:

b. 3-way valve:
c. 4-way valve:
C. Based on mode of actuation:
a. Manually operated(actuated) valve:

b. Mechanically operated(actuated) valve:

c. Solenoid operated valve:
Spool type DCV can be actuated using solenoid as shown in fig.
A solenoid is made up of 2 basic parts, a coil and an armature. Applying
electrical signals to the coil, coil is energised and creates magnetic field which
attracts the armature towards it.This causes the armature to push the spool of
the valve either for opening or closing the flow path.
d. Pilot operated valve:
In large hydraulic valves, the operating force required to move the spool
can be large or in some hydraulic systems operating pressure and flow
can be high. Due to the high pressure of the system force required to
actuate the DCV will be high. In such a case pilot operated valves are
used.
This system uses two valves. One is called main operating valve
or master valve, the other is called pilot operated valve(slave valve).
When the pilot valve is operated by solenoid. When the solenoid
operated valve is actuated it sends a pilot signal to operate the main
valve as shown in fig. Both master and slave valves will be usually
housed in one block or one module.
Pressure Control Valves(PCVs):
PCVs are used to control the pressure of the flow of the fluid, power
wastage and overheating of the hydraulic system.
The main functions of PCVs are:
1. Limiting maximum system pressure at a safe level
2. Regulating/Reducing pressure in certain portions of the circuit
3. Unloading system pressure
4. Reducing or stepping down pressure levels from the main circuit to a
lower pressure in a sub-circuit
5. Assisting sequential operation of actuators in a circuit with pressure
control
6. Any other pressure related function by virtue of pressure control.
Classification of Pressure Control Valves:
1. Pressure Relief Valve
2. Pressure Reducing or Regulating Valve
3. Pressure Unloading Valve
4. Pressure Sequencing Valve
5. Pressure Counter-balancing Valve
NOTE:
All of these are normally closed valves, except for reducing valves,
which are normally open.
For most of these valves, a restriction is necessary to produce the
required pressure control.
One exception is the externally piloted unloading valve, which
depends on an external signal for its actuation.
1. Pressure Relief Valve or Pressure Limiting Valve:
Pressure relief valve is a safety valve which is used to limit the system
pressure to a prescribed (Preset) pressure by diverting some or all output
quantity of the fluid coming from pump to the tank when the pressure
reaches a preset level.
Relief valve protects the hydraulic system from excessive fluid
pressure over and above the design/set pressure.
Function:
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.
A ball is held seated inside the valve by a heavy spring, When
system pressure acts on the ball is more than the spring force then the
ball moves out of the seat thereby allowing the fluid to go back to the
tank as long as this high pressure is maintained. The valve spring force
can be adjusted by means of screw.
(Limits the maximum pressure in system. Usually connected to pump. It
is normally closed valve)
2. Pressure Reducing or Regulating Valve:
A pressure reducing valve is normally an open valve, It is used to
maintain reduced pressures in specified locations of hydraulic systems.
It is usually actuated by downstream pressure and tends to close
(closes) as this pressure(down stream pressure) reaches the valve setting
as shown in fig.
Function:
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 outlet.
When the outlet(downstream) pressure increases to the valve
setting, the spool moves to the right to partially blocks the outlet port.
If the valve is closed completely by the spool, it could cause the
upstream pressure to build up above the valve setting. To avoid this, a
drain line is provided to drain the fluid to the tank.
(Maintains a prescribed reduced pressure at its outlet regardless of the
valve inlet connection. It is normally an open valve)
3. Pressure Unloading Valve:
Pressure unloading valve is similar to pressure relief valve. In case of
pressure unloading valve, pilot control is from the remote system
pressure.
Pressure unloading valve is pressure control device, which is used
to dump excess fluid to the tank at little or no pressure.
(Limits the maximum pressure in system. Usually connected to pump. It
is normally closed valve. Similar to pressure relief valve but closing of
valve is controlled by remote pilot)
Pressure Unloading Valve:
Function:
It consists of a spool held by the spring force on one side and the other
side by the remote pilot pressure.
When the remote pilot pressure exceeds (crosses) the spring
force, and as long as this condition exists, the delivery from the pump
goes to the tank.
An unloading valve is used in process to do operations like
stamping, coining, punching and piercing, etc.
4. Pressure sequence valve: (Directs the flow in more than one portion
of a fluid circuit in sequence)
Pressure sequence valve is used in a hydraulic system to cause various
operations in a sequential or definite order i.e., one after the another
with many actuators in the hydraulic system.
Eg: The sequence may be clamping the job followed by machining
operation.
Sequence valve is normally closed, It consists of a spool held by
the spring force on one side and the other side by the remote pilot
pressure.
1. In this valve the fluid flow freely through the primary port (circuit)
to operate (perform) its first function until the valves pressure
setting(preset pressure) is reached
2. Once preset pressure is reached, the spool moves to the right spring
is compressed, the flow of fluid is diverted to the secondary port
(circuit) to operate (perform) its second function.
5. Pressure Counter-Balance Valve: (Permits free flow in one direction
and restricted flow in the opposite direction)
The purpose of a counterbalance valve is to maintain control of vertical
hydraulic cylinder to prevent it from descending due to weight of its
external load.
The primary port of this valve is connected to the bottom of the cylinder,
and the secondary port is connected to a directional control valve(DCV)
The pressure setting of the counterbalance valve is somewhat higher
than is necessary to prevent the cylinder load from falling due to its weight.
Working: When pressure fluid flows to the cylinders cap end, the cylinder
extends increasing pressure in the rod end and shifting the main spool in the
counter balance valve. This creates a path which permits fluid to flow
through the secondary port to the DCV and to reservoir. As the load is
raised, the internal check valve opens to allow the cylinder to retract freely.
Counter balance valves are usually drained internally.
NAME SYMBOL FUNCTION
Pressure Relief Limits the maximum pressure in
Valve system. Usually connected to
pump. It is normally closed valve

Pressure Reducing Maintains a prescribed reduced

Valve pressure at its outlet regardless of
the valve inlet connection. It is
normally an open valve
NAME SYMBOL FUNCTION
Pressure Unloading Limits the maximum pressure
Valve in system. Usually connected
to pump. It is normally closed
valve. Similar to pressure
relief valve but closing of
valve is controlled by remote
pilot

Pressure Sequence Directs the flow in more than

Valve one portion of a fluid circuit
in sequence
NAME SYMBOL FUNCTION
Pressure Counter- Permits free flow in one
Balance Valve direction and restricted
flow in the opposite
direction
Flow Control Valves(FCV):
FCVs are used to control the rate of flow of fluid in a hydraulic circuit.
They are also called as volume control valves or speed control valves.

Functions of Flow Control Valves(FCVs):

FUNCTIONS OF FLOW CONTROL VALVES(FCVs):
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

2. Regulate the power available to the sub-circuits by controlling the flow to

them:
Power (W) = Flow rate (m3/s) Pressure (N/m2)
P = Qp
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.
Factors affecting the flow rate of a fluid are
a. Orifice size or opening
b. Pressure of fluid
c. Temperature of fluid
Classification of Flow control valves(FCV):
1. Non-Pressure compensated valves
2. Pressure compensated valves
1. Non-Pressure compensated FCVs:
Non-pressure-compensated flow-control valves are 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.
Advantages:
1. Simple in construction and design
2. Easy to operate and control
Limitations:
1. Accuracy in speed control is not possible
2. Precise control is not possible
3. Leakage in the valve affects the performance
.
a. Needle Valve:
Needle valve is most commonly
used hydraulic flow-control valve.
This consists of a needle or pointed
stem that can be adjusted manually
to control the discharge. These
valves are often made out of steel
and are also used as stop valve to
prevent/reduce flow of fluid from
one part in the hydraulic circuit to
another part.
b. Globe valve:
This is a basic 2-way valve. This
consists of a circular disc at the end of a
threaded stem. as shown in fig.
The area for flow of fluid is much
larger in this valve when compared to a
needle valve and hence the flow
capacity is larger at a lower pressure
drop than a needle valve of same size.
Since the area of flow is not so
gradually reducing as in the case of
needle valve.
c. Gate Valve:
This has a large rectangular plate which
serves as a gate between the inlet and
outlet of the valve. The gate is freely
mounted to a threaded stem as shown in
fig.
The threaded portion of the stem
operates in the matching internal thread
provided in the body of the valve. This
in turn moves the gate up and down, for
opening and blocking the passage.
Gate valves provides much
larger opening than needle and globe
valves resulting in much larger flow
capacity at a lower pressure drop.
2. Compensated Flow Control Valves:
To achieve constant discharge or flow, the flow should be pressure
compensated or temperature compensated or both. Such a flow control
valve is called compensated flow control valve.

Classification of compensated flow control valve:

1. Pressure compensated flow control valve
2. Temperature compensated flow control valve
3. Both Pressure and Temperature compensated flow control valve
1. Pressure compensated flow
control valve:
Pressure compensated FCV
automatically adjusts the size of the
orifice in response to changes in
working load and pressures and
maintains a constant pressure drop
across the orifice.
 2. Temperature compensated flow control valve:

As the viscosity ofthe increase in

oil varies withtemperature causes
temperature, theincrease in flow
oil becomes lowfor a valve setting,
viscous whenso temperature
temperature compensation is
increases. As theneeded to offset
less viscous fluidthe effect of such
flows more rapidlytemperature
through an orifice,variations.
Pressure and Temperature compensated FCV: