Fluid Power System [MEng4262]

Chapter-5
Control components in hydraulic system
Introduction
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 through the use of control devices called valves. The selection
of these control devices involves not only the type but also size, the actuating technique, and
remote-control capability. There are three basic types of control devices:

1. Directional control valves

2. Pressure control valves
3. Flow control valves

Directional control valves 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, shuttle
valves, and two-way, three-way, and four-way directional control valves.

Presure control valves protect the system against overpressure, which may occur due
to gradual buildup as fluid demand decreases or due to a sudden surge as valves open or
close. The gradual buildup of pressure is controlled by pressure relief, pressure reducing,
sequence, unloading and counterbalance valves. Ofcourse, pressure-compensated pumps can
also be used. Pressure surges can produce an instantaneous increase in pressure as much as
four times the normal system pressure. Shock absorbes are hydraulic devices designed to
smooth out pressure surges and to dampen out hydraulic shock.

In addition, fluid flow rate must be controlled in various lines of a hydraulic circiut.
For example, the control of actuator speeds depends on flow rates. This type of control is
accomplished through the use of flow control valves. A variable displacement pump can also
be used to control actuator speed unless the system contains several actuators, each of which
must operate at different speeds. In such a case seperate flow control valves are required. Non
compensated flow control valves are used where precise speed control is not requied since
flow rate varies with pressure drop across a flow control valve. Pressure- compensated flow
control valves automatically adjust to changes in pressure drop to produce a constant flow
rate.

It is important to know the primary function and operation of the various types of control
components. This type of knowledge is not only required for a good functioning system, but
it also leads to the discovery of innovative ways to improve a fluid power system for a given
application. This is one of the biggest challenges facing the fluid power system designer.

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Figure: 5.1 show internal operation of valves.

 To extend the ram, ports P and B are connected to deliver fluid and

 Ports A and T connected to return fluid.

 To retract the ram, ports P and A are connected to deliver fluid and

 Ports B and T to return fluid.

Figure: 5.1

Three basic types of control devices:

 Direction Control Valves (control the fluid path)

Control the direction of flow of the hydraulic fluid to different lines in the circuit

 Check Valves

 Shuttle Valves

 2-Way, 3-Way, 4-Way DCV

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• Pressure Control Valves (protect system)

Control the pressure in different segments in the circuit

 Flow Control Valves (speed control)

Control the amount of fluid flow in the circuit

Direction Control Valves

CHECK VALVE /non-return valve

 The simplest type of DCV which is a two way valve b/c it contains two ports.

 Its purpose is to permit free flow in one direction & prevent any flow in other
direction.

Figure: 5.2

Figure: 5.3 Symbolic representation

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The second type of check valve is Pilot operated check valve

Pilot check valves are frequent used for locking hydraulic cylinders in position.

In the design shown in figure 5.4, the check valve poppet has the pilot piston attached to the
threaded poppet stem by a nut. The light spring holds the poppet seated in a no-flow
condition by pushing against the pilot piston.

Symbol representation

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Figure 5.4

Shuttle Valve

Figure 5.5

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Symbolic representation

Shuttle valves are common for pneumatics and little use in hydraulic system.

 A shuttle valve has two fluid inlets ‘P1’ and ‘P2’ and one fluid outlet ‘A’.

 When compressed fluid enters through ‘P1’, the sphere will seal and block the other
inlet ‘P2’.

 Fluid can then flow from ‘P1’ to ‘A’.

 When the contrary happens, the sphere will block inlet ‘P1’, allowing fluid to flow
from ‘P2’ to ‘A’ only.

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.

Figure: 5.6

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DIRECTIONAL CONTRIOL VALVES:

Ways or Ports

 Two-Way Valves

 Used to direct pump flow to either of two paths of circuit.(Single acting

cylinder)

 Three -Way Valves – which contain three ports, are typically of spool design rather
than poppet design. (Single acting cylinder)

 Four-Way Valves

 Used to control double acting hydraulic cylinders

 The number of ports in a DCV is identified by the term way. Thus, for example, a
valve with four ports is a four-way valve.

DIRECTIONAL CONTRIOL VALVES:

Positions

• Common types of directional control valves include 2/2, 3/2, 4/2, 4/3, etc.

• The first number represents the number of ports; the second number represents the
number of positions.

Figure: 5.7

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Three -Way Valves (3/2 DCV)

Three way, two position, manually operated spring return

Figure: 5.8

4 way valves, 2 positions

Four way valves have four connections to the circuit. The designations P for pressure, T for
tank, and A and B for ports on either end of the cylinder are commonly used on four-way
valves.

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4 way 3 position (4/3) open centered DCV

4/3 Tandem centered DCV: mid position

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4/3 Closed center DCV

Regenerative center 4/3 DCV

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Floating center 4/3 DCV: mid position

Directional control valve Method of Actuation

Manually

 Push button

 Lever

 Pedal

Mechanically

 Spring

 Ball and Cam

Using pilot pressure

 Air (pneumatic)

 Oil (hydraulic)

Using Electrical Solenoid

Manually actuated, spring centered, 3-position, 4-way valve (Hand lever)

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Two-position, spring-offset, four-way valve

Mechanically actuated 4-way valve, 2 position, spring offset

valve

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(Cam driven roller mechanism)

Air pilot-actuated, four-way ,3 position, spring centered valve

Operation of Solenoid to shift Spool

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Pressure Control Valves

 Main function of pressure control valve is ensuring the control of pressure.

• Pressure regulating: maintaining a constant pressure in a system

• Pressure switching: apart from a definite control function they also perform a
switching action

 Usually named for their primary function as

• Pressure relief valve,

• unloading valve,

• Sequence valve

• counter balance valves,

• Pressure reducing valve,

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Pressure relief valve

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.

Unloading valve
 An 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.

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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.

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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.

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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.

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Flow Control Valves

 Main function of flow control valve is to regulate the

actuators depending on flow rates.

 A flow control valve is formed by a non-return valve and a

variable throttle.

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