Chapter 2 : Control Valves - Components of Hydraulic System

(Notes by Avtar Krishna, XIPT)

A Valve is a device that regulates, directs or controls the flow of fluid ( liquids or gases)
by opening, closing or partially obstructing various passage ways.

Functions:

Stopping and starting of flow

Reduce or increase of flow.

Controlling direction of flow.

Regulating a flow pressure.

Directional control valves :

Directional control valves (DCVs) are one of the most fundamental parts of hydraulic
and pneumatic systems.

DCVs allow fluid flow (hydraulic oil, water or air) into different paths from one or more
sources.

DCVs will usually consist of a spool inside a cylinder which is mechanically or

electrically actuated. The position of the spool restricts or permits flow, thus it controls
the fluid flow.

Directional control valves perform only three functions:

stop fluid flow

allow fluid flow, and

change direction of fluid flow.

Classification:

Directional control valves can be classified according to-

number of ports
number of positions

actuating methods

type of spool.

Poppet Valve

Poppet valves are directional control valves that are fitted into housing bores with a
threaded connection.

In a poppet valve, simple discs, cones or balls are used in conjunction with simple valve
seats to control flow.

It is also called Mushroom valve.

Poppet valves are used in most piston engines to open and close the intake and exhaust
ports of in the cylinder head.
 Poppet valves (ball type)

Figure shows the construction and symbol of a simple 2/2 normally closed valve, where
depression of the pushbutton lifts the ball off its seat and allows fluid to flow from port P
to port A.

When the button is released, spring and fluid pressure force the ball up again, closing the
valve.

Poppet valves disc type

Figure shows the construction and symbol of a disc seal 3/2 poppet.

When the push button released, ports A and R are linked via the hollow pushbutton stem.

If the pushbutton is pressed, port R is first sealed, then the valve disc pushed down to
open the valve and connect ports P and A. As before, spring and fluid pressure from port
P closes the valve.

Spool valve:

A hydraulic spool valve is a switching device used to control the hydraulic devices.

A spool valve can turn the flow of hydraulic fluid from pump to an actuator on and off by
blocking of the route the fluid takes.

Spool valves have two elements: a cylindrical barrel in which slides a plunger. Port
blocking is provided by lands or full diameter sections on the spool, separated by waisted
sections which provide port interconnections through the barrel. This provides multi-way
and multi-position switching.
 3/2 spool valve

A 3/2 valve has 3 ports or opening 1( Pump), 2(Actuator) and 3( Reservoir or Tank).

In one extreme position of spool, the pump port P (1) is blocked and actuator port (2) is
connected to the Tank port (3). They allow the outlet to flow back to the tank when the
pump P is blocked.

In another position of spool, the pressure fluid flows from port P to actuator port A
remaining the tank port T closed.
 4/2 DCV

4/2 valve has four connections to it and two valve positions.

4/2 valve has only 1 exhaust port, 1 inlet port and 2 working ports.

As the 4/2 valve has only 1 exhaust port, that means the oil from both the working ports
inside the valve has to be directed to the same exhaust port (goes to reservoir only).

5/2 dcv

A 5/2 way directional valve from the name itself has 5 ports equally spaced and 2 flow
positions.

5/2 Hydraulic valves are used for controlling double acting cylinders.
 They have 2 output ports, commonly designated A & B or 2 & 4. They have one inlet
port, designated P or 1, and two exhaust ports, designated R & S or 3 & 5.

Flow control valve (fcv)

A flow control valve regulates the flow or pressure of a fluid.

In hydraulic systems, they’re used to control the flow rate to motors and cylinders,
thereby regulating the speed of those components.

FCV maintain a preset flow rate and/or limit the maximum flow rate regardless of
changing upstream and downstream pressures.
Classification:

 Non pressure compensated flow control valve

 Pressure compensated flow control valve

Non pressure compensated FCV:

Non pressure compensated flow control valves will be usually used where system
pressure is relatively constant.

Non pressure compensated flow control valve is the simplest form of flow control valve.

Such valve will have one adjustment screw with needle type of end. Flow rate of
hydraulic oil will be changed by changing the orifice opening and Orifice opening will be
changed by turning the adjustment screw.

Non-pressure-compensated flow-control valves are used when the 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.

When the load on the actuator changes significantly, the system pressure changes. Thus,
the flow rate through the non-pressure-compensated valve will change for the same flow
rate setting.
It consists of a screw (and needle) inside a tube-like structure. It has an adjustable orifice
that can be used to reduce the flow in a circuit.

The size of the orifice is adjusted by turning the adjustment screw that raises or lowers
the needle. For a given opening position, a needle valve behaves as an orifice.

Pressure compensated fcv

Pressure-compensated flow control valves are designed to provide a constant volume

flow rate independent of the pressure drop across the valve.

Pressure-compensated flow control valves are also useful in maintaining constant rpm of
a hydraulic motor independent of load on the motor.

Pressure-compensated flow control valves can compensate for pressure fluctuations on

either the supply side (inlet) or the load side (outlet) of the valve.
A pressure-compensated flow control valve typically consists of a variable orifice and a
pressure compensator within a single valve body.

The overall path that fluid takes through the pressure-compensated valve is from the
supply through the inlet and compensator orifice, around the compensator spool, through
the variable orifice and out the outlet

The desired flow rate is set on the variable orifice by adjusting the pass-through area of
the orifice. This adjustment can be made manually by means of a knob, screw or lever on
the valve or remotely with solenoid actuator attached to the variable orifice.

The pressure compensator automatically adjusts the size of the orifice between the inlet
flow and compensator spool, modulating the flow of fluid that enters the valve to
maintain a constant pressure drop across the variable orifice, providing a constant flow
rate through the valve.

Pressure relief valve (prv)

Pressure relief Valve is one of the most important type of safety valve.

This type of valves sets a limit on the rise of pressure within a hydraulic line.

In normal operation the valve is closed and no fluid passes through. But if the pressure in
the line exceeds the limit the valve opens to relieve the pressure. This protects expensive
machinery such as motors, pumps and actuators from becoming damaged from high
pressure.
Working:

If pressure at the inlet of relief valve is not enough to overcome the spring force, in that
situation poppet will be remain seated over its seat and will not allow the flow of fluid
through it and therefore relief valve will be closed and will not allow flow through it.

When pressure at the inlet of relief valve increases and overcomes the spring force which
was adjusted with the help of pressure adjusting screw displayed at the top of relief valve,
in that situation poppet will leave the seat and will permit the flow of fluid through relief
valve.
Hence, if pressure at inlet of relief valve overcomes the setting pressure of relief valve
then fluid will flow to hydraulic reservoir
 Pressure reducing valve

Pressure reducing valve is a type of pressure control valve.

This type of valve is used to maintain constant reduced pressure in a pipeline where the
flow is fluctuating.

This type of valve is used to maintain reduced pressures in specified locations of

hydraulic systems. The high incoming pressure is reduced to a constant pressure level to
protect the important instrument.
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.

The pressure entering the main valve assists the main valve spring in keeping the
reducing valve closed by pushing upward on the main valve disk

Sequence valve

Sequence valves control the sequence of operation between two branches in a circuit; that
is, they enable one unit to automatically set another unit into motion.

The sequence valve diverts the fluid to a second actuator or motor to do work in another
part of the system.

A sequence valve is a pressure-operated, normally closed, poppet or spool valve that

opens at an adjustable set pressure.
An installation of two sequence valves that control the sequence of operation of three
actuating cylinders.

Fluid is free to flow into cylinder A. The first sequence valve (1) blocks the passage of
fluid until the piston in cylinder A moves to the end of its stroke.

At this time, sequence valve 1 opens, allowing fluid to enter cylinder B. This action
continues until all three pistons complete their strokes.

Counter balance valve

Counter Balance Valve It is basically a relief valve but it is used to set up a back pressure
in a circuit to prevent load from falling.

The counterbalance valve, also called a holding valve, is used to prevent a weight from
falling uncontrollably.

They are frequently employed in vertical presses, loaders, lift trucks and other machines
that must maintain a particular position or hold a suspended load.

In such applications, the counterbalance valve creates a back pressure to prevent the
movement of piston rod of cylinder.
When the pump is off, the counter balance valves prevents the load from falling under
gravity by maintaining back pressure against the load. When the pump is on, fluid flows
through the check valve which offers little resistance to flow, and the load can be
elevated.

When the DCV is moved to the right envelop, the counterbalance valve opens, but offers
resistance to flow that is adjustable by spring setting. This prevents the load from falling
rapidly.