Fluid Power Engineering– 0908463

Chapter 6: Hydraulic Valves

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 • Valves are the main components to control any fluid power systems. If control
components are not properly selected, the entire system will not function as
required.

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 • They are used to control the direction of flow in a hydraulic circuits.
• Two-way valve (2/2)

Symbol

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 • The inlet is denoted as “P” and the outlet port as “A”.
• The right hand shows the valve in its closed position.
• The left hand square shows the valve in its “operated”, “switched” or
“actuated” position.
• A 2/2 valve indicates that the valve has two ports and two positions
(states).

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 • Consider, a circuit including a power pack and a 2/2 valve.
• When the valve is open, the flow goes to the tank through the valve.
Therefore, the pressure would be the tank pressure if the losses are
ignorable.
• However, as soon as the valve is placed in the right state, pressure builds up
in the system, if and only if there is no other outlet port to the tank.

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 • Consider, a circuit including a power pack and a 2/2 valve.
• When the valve is open, the flow goes to the tank through the valve.
Therefore, the pressure would be the tank pressure if the losses are
ignorable.
• However, as soon as the valve is placed in the right state, pressure builds up
in the system, if and only if there is no other outlet port to the tank.

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 • 𝒏-way, 𝒎- position spool valves
• Referring to 2/2 valve, it might be possible to fabricate any possible
combination of states and ports in a valve. However, the technical
constrains don't allow developing such a valve.

• For naming the valve, we use the following strategy.

• If there are 𝑛 ports and 𝑚 positions in a valve, it is so-called 𝑛/𝑚 valves.
However, there are several common spool valves in hydraulic industry as:
3/2, 4/2, 4/3, 5/3

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 • 𝟑/𝟐 𝒗𝒂𝒍𝒗𝒆
• 3/2 valve is normally placed in the closed states in which P is blocked.

Symbol

◦ 3/2 valves are typically used to control a single-acting cylinder.

◦ When the button is pressed, port A is connected to P and cylinder extends.
◦ As soon as the button is released, the spring force of the cylinder causes
the oil to be discharged through other state of the valve in which port A is
connected to the tank.

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 • 𝟑/𝟐 𝒗𝒂𝒍𝒗𝒆

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 • Consider, a circuit including a power pack and a 2/2 valve.
• When the valve is open, the flow goes to the tank through the valve.
Therefore, the pressure would be the tank pressure if the losses are
ignorable.
• However, as soon as the valve is placed in the right state, pressure builds up
in the system, if and only if there is no other outlet port to the tank.

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 • 4/𝟐 𝒗𝒂𝒍𝒗𝒆

Symbol

◦ In the normal state, port P is open to B and A is open to T.

◦ When the spool moves into the second position, P is open to A and
◦ B is connected to T.

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 • 4/𝟐 𝒗𝒂𝒍𝒗𝒆
◦ 4/2 valves are typically used to control a
double-acting cylinder.
◦ In the shown circuit, when the button is
pressed, port A is connected to port P
and cylinder extends.
◦ As soon as the button is released Port A
is connected to the tank and
◦ port B is connected to P. Therefore, the
cylinder retracts.

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 • 4/𝟑 𝒗𝒂𝒍𝒗𝒆
◦ The middle position is normally activated.
◦ When the right position is activated, port P is
connected to port B, and Port A is connected to T. Symbol
◦ In contrast, when the left position is activated, port
P is open to A and Port B is open to T.
◦ There are several configurations for the middle
state as seen in the figures below.

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 ◦ The question is how to activate a spool valve. There are five main methods
for the valves actuating as:
◦ 1- Manual
◦ 2- Mechanical
◦ 3- Electrical
◦ 4- Pressure pilot Manually
◦ 5- Spring.

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 • Example: Label the shown valves:

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 Directional control valves can be classified according to the following:

◦ Internal control element structure: the internal control element in directional

valves may be a sliding spool, rotary spool, poppet or ball.

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 Directional control valves can be classified according to the following:

◦ Number of ports or ways: the number of ports in a directional control valve is

identified by the term way. Thus, for example, a valve with four ports is a
four-way valve.

◦ Number of positions: the positions in a directional control valve determines

the number of alternative flow conditions the valve can provide.

◦ Method(s) of actuation.

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 • Example: For the directional control valve below, identify the following:
• Internal control element
• Number of ways
• Number of positions
• Sketch the symbol of the valve

A B

T P T

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 • Purpose: to permit free flow in one direction and prevent any flow in the
opposite direction.
• It consists of:
1. Inlet
2. Outlet
3. Poppet valve and seat
4. Spring

Free flow No flow

direction direction

Symbol
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 • Purpose: Hydraulic pilot pressure allows this mechanical device to push the
poppet (3) off its seat to allow reverse flow.
• Function: If Ppilot >Ppreset, then allow reverse flow
• It consists of:
1. Inlet port
2. Outlet port
3. Poppet
4. Poppet spring
5. Pilot port
6. Piston with rod
7. Piston spring
Symbol
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 • A pilot operated check valve always permits
free flow in one direction, and permits flow
in the normally blocked direction if pilot
pressure is applied to the pilot pressure port
of the valve.

• The dashed line in the symbol represents the

pilot pressure line connected to pilot
pressure port of the valve

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 • During retraction, flow from Port B goes to the cylinder through the check
• valve, and the load is lifted.

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 • During extension,
1. flow from Port A pushes the cylinder down but the cylinder is locked by the
check valve.
2. Pressure builds up and the check valve will allow reverse flow when the
pressure reaches the preset value of the pilot-operated check valve.
3. When the pilot valve is opened, the load may pull the piston faster than
supplied fluid can fill in the cylinder. This will reduce pressure, and close the
pilot-operated check valve.
4. Procedure 2 and 3 will be repeated until the cylinder is fully extended.

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 • This valve is also called “OR valve”.

Symbol

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 • Flow control valves are used to regulate the speed of hydraulic cylinders
and motors by controlling the flow rate to these actuators.

• They may be as simple as a fixed orifice (a disk with a hole through which
fluid can flow), or an adjustable orifice.

• An orifice is a disk with a hole through which fluid can flow. An orifice can
be used as a flow meter by measuring the pressure drop across the orifice.

fixed orifice
variable orifice

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 • An orifice installed in a pipe can be used as a flowmeter by measuring the
pressure drop across the orifice. For an orifice, there is a relationship
between the pressure drop and flow rate as:

• where Q is flow rate, C is flow coefficient (0.8 for sharp edge, 0.6 for square
edge), A is the area of orifice opening, p pressure, and SG is specific gravity
of the fluid.

• This phenomenon is used for

the flow controlling.

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 • Needle valve is most commonly used for flow control because it has more
precise adjustment and flow characteristics. The orifice can be changed
gradually due to the fine threads on the adjusting screw and the shape of
the needle or cone.

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 • Purpose: Restricted flow rate is in one direction, free is in the
opposite direction.
• Method: In the simple needle valve, the variable orifice would also
have an effect on the flow in the reverse direction. To enable the fluid
to flow unrestricted in the reverse direction, a check valve is
incorporated within the valve body.
• Flow rate control: by turning the needle valve, the orifice opening
area is controlled, which leads flow rate change.
• Limitation: Since pressure drop may not be constant, flow rate
depends on pressure.
• Applications:1-pressure is relatively constant 2-Monitoring speed is
not critical.
• This valve is usually called: Flow Control Valve (FCV).

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 • Purpose: maintain a constant flow rate regardless of pressure change.
• Design: In order to keep the flow rate constant, the pressure drop across the orifice
must remain constant. The pressure drop deviation is adjusted using a feedback line and
a spring.
• Spring: has almost constant force, which is represented in psi based on the spool area (P
= F/A).

• 1- needle valve
• 2- compensator spool
• 3- spring

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 • Purpose: Maintains a constant flow rate for a wide temperature range.
• Fluid viscosity changes due to temperature variation. Temperature rise reduces
viscosity, which increases the flow rate. This will also increase actuator speed. When a
precise actuator speed is required, this valve can be used to maintain the flow rate due
to the change in fluid temperature.
• Method: Using a temperature sensitive rod with an orifice, flow rate can be maintained
for a wide range of temperature.

• 1 – temperature sensitive rod

• 2 – valve section

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 • Purpose: Protects the circuit from high pressure
• Function: Sets the maximum working pressure of the hydraulic system
• Method: When the system pressure exceeds the preset pressure (Adjustable using
screw(4)), the valve opens, and oil returns to the tank.
• Normally closed.

• The poppet type (direct pressure relief

valve) consists of:
• 1. A ball
• 2. A seat
• 3. Spring
• 4. Adjustment screw

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 • The pressure relief valve provides protection against overload experienced by the
actuators in a hydraulic system. One important function is to limit the force or torque
produced by the hydraulic cylinders or motors.
• The pressure when the valve opens enough to allow full pump flow can be substantially
greater than the cracking pressure. The pressure at full pump flow is the pressure level
that is specified when referring to the pressure setting of the relief valve. It is the
maximum pressure permitted by the relief valve, and should be set around the
maximum working pressure of the system.

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 • The spool type relief valve consists of a spool, spring and adjusting screw.
• The pressure between the spool lands is balanced as the areas are the same.

F  0
T A

F fluid  Fspring  0
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 • Example 8.1: A pressure relief valve with a poppet area of 0.75 in2 and a spring constant
of 2500 lb/in has its spring is initially compressed by 0.2 in. The poppet must move by
0.1 in from its fully closed position in order to pass full pump flow through the valve.
1. Determine the cracking pressure of the valve.
2. Determine the pressure of the valve needed for full pump flow through the valve.

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 • A compound pressure relief valve is one that
operates in two stages. It consists of
1. Spool
2. Orifice
3. Seat
4. Light spring
5. Dart
6. Seat
7. Bias spring
8. Adjustment screw
9. Drain.

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 • Example 8.1: A pressure relief valve has a pressure setting of 5000 kPa. Calculate the
power loss in the valve if it returns all the pump flow (2 x 10 -3 m3/s) to the tank.

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 • Purpose: Sets a secondary pressure on the system.
• Design: This valve senses “downstream” pressure to provide a constant pressure on the
outlet port.
• Spring: provide almost constant force.

• The valve consists of

1. spool
2. spring
3. adjustment screw
4. primary inlet port
5. secondary outlet port
6. feedback line

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 • Exercise: Mention the main differences between pressure relief valve and pressure
reducing valve.

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 • Purpose: directs flow back to the tank when the pressure from port ‘A’ in a remote part
of the system reaches a predetermined level.
• Function: If PA >Ppreset, then open flow from Port ‘P’ to tank.
• This is one method of unloading a pump to reduce output power when actuators are at
rest for a period of time.

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 • Purpose: Allows one operation to take place before another.
• Method: Valve will not open until the preset pressure is reached. The sequence valve
• operation is similar to the operation of a pressure relief valve, but the outlet port is
• connected to other operation line rather than the tank.
• Function: If PA >Ppreset, then allow flow to Port ‘B’.

A
A
A

B
T B
T B

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 • Sequence valves are
used to direct fluid in a
sequential manner. A
typical application is to
control the sequence in
which two actuators
are to operate.

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The University of Jordan
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 • A counterbalance valve permits free flow in one direction, and a restricted flow in the
opposite direction. It is commonly used in conjunction with a single acting cylinder that
elevates and lowers a load.
• Method: This valve allows flow from one direction (Port B to Port A) but need to reach
the preset pressure to open on the opposite direction (Port A to Port B).

• Due to the weight of the load, the piston may be pulled faster than supplied fluid, which
may create cavitation in the upper side of the cylinder. To prevent cavitation, a
counterbalance valve needs to be used.

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 • A servo valve is a directional control valve that has infinitely variable positioning
capability. Thus, it can control not only the direction of fluid flow but also the amount of
flow. Servo valves are coupled with feedback-sensing devices, which allow very accurate
control of position, velocity, and acceleration of an actuator.
• Mechanical Feedback.
• Electro-hydraulic feedback.

Mechanical Feedback.
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