Chapter 10.

Hydraulic Valves

10.2.3 Unloading valve

Unloading valves are pressure-control devices that are used to dump excess fluid to the tank at little or no pressure.
The circuit then shifts to a single pump providing a high pressure to perform work. Schematic diagram of unloading
valve is shown in Fig. 10. 11. An unloading valve unloads the pump when the desired pressure is reached. It allows
rapid discharge of pressurized oil near atmospheric pressure. As soon as the system pressure reaches the setting
pressure that is available at the pilot port, it lifts the spool against the spring force. When the spool is held by the pilot
pressure, the delivery from the pump goes to the tank. Fig. 10.11(C) shows a common application of high-low pump
circuits where two pumps move an actuator at a high speed and low pressure.

(a) Operation of unloading valve and symbol

(b) Shape of unloading valve

 (c) Application circuit of unloading valve (double-pump hydraulic system)

Figure 10.11 Operation and application of unloading valve

10.2.4 Counterbalance valve

Counterbalance valves are commonly used to counterbalance a weight or external force or counteract a weight such
as a platen or a press and keep it from freefalling. Schematic diagram of counterbalance valve is shown in Fig. 10.12.
These normally closed valves are primarily used to maintain a back pressure on a vertical cylinder to prevent it from
falling due to gravity. They are used to prevent a load from accelerating uncontrollably. This situation can occur in
vertical cylinders in which the load is a weight. Valve’s primary port is connected to the cylinder’s rod end and the
secondary port to the directional control valve. The pressure setting is slightly higher than that required to keep the
load from free-falling. When the pressurized fluid flows to the cylinder’s cap end, the cylinder extends, increasing
pressure in the rod end and shifting the main spool in the counterbalance valve. This creates a path that permits the
fluid to flow through the secondary port via the directional control valve and to the reservoir. As the load is raised, the
integral check valve opens to allow the cylinder to retract freely.

(a) Operation of counterbalance valve and symbol

 (b) Shape of counterbalance valve

(c) Application circuit of counterbalance valve

Figure 10.12 Operation and application of Counterbalance valve

Example 10.2
In the counterbalance circuit, load to be lifted is 10kN and a cylinder bore area of 0.002m2 (equivalent to 50 mm
diameter) is used. Calculate the setting pressure of counterbalance valve if the primary port opening pressure is 1.3
times higher than the load-induced pressure.
Solution:
10×103 [N]
Load induced pressure = = 50bar
0.002[m2 ]

Counterbalance valve setting = 50 × 1.3 = 65bar

10.2.5 Pressure-sequence valve

A sequence valve is a pressure-control valve that is used to force two actuators to operate in sequence. They are similar
to pressure-relief valves. Schematic diagram of sequence valve is shown in Fig. 10.13. Instead of sending flow back
to the tank, a sequence valve allows flow to a branch circuit, when a preset pressure is reached. The check valve allows
the sequence valve to be bypassed in the reverse direction.
The hydraulic circuit shown in Fig. 10.13(c-1) is an example of an application of a sequence valve in which a clamp
cylinder extends first and then a second cylinder extends to hold a workpiece. In this circuit, two cylinders are
connected in parallel. Without the sequence valve, these cylinders would extend together as they are both unloaded.
In order for this circuit to function properly, the cylinder 1 must extend completely before the cylinder 2 begins to
extend. The sequence valve accomplishes this by not allowing flow into the cylinder 2 branch of circuit until the
cylinder 1 has reached the end of its stroke. When the cylinder 1 extends completely, the pressure rises and opens the
sequence valve, thus allowing the cylinder 2 to extend. The sequence valve must be set high enough so that it opens
only after the complete extension of the clamp cylinder. During the retraction of cylinders, the check valve allows the
sequence valve to be bypassed. The sequence valve has no effect on the circuit in this situation. Both cylinders retract
together because both are unloaded and split the pump flow.
The hydraulic circuit shown in Fig. 10.13(c-2) is a similar application example of an of a sequence valve using
clamping cylinder and drilling cylinder for drilling work. One cycle of processing sequence is as followings

1. Initially, two cylinders are at retracted position.

2. Clamping cylinder is extending to clamp a workpiece.

3. After clamping the workpiece, drilling cylinder is extending to drill the workpiece.

4. After finishing drill work, drilling cylinder is retracting.

5. After retracing drilling cylinder, clamping cylinder is retracting to unclamp a workpiece.

(a) Operation of pressure sequence valve and symbol

(b) Shape of pressure sequence valve

(c-1) Application circuit of counterbalance valve
(C-2) Detailed process of application circuit using counterbalance valve

Figure 10.13 Operation and application of counterbalance valve

10.3 Flow control valves
Flow-control valves control the rate of flow of a fluid through a hydraulic circuit. Their function is to provide velocity
control of linear actuators, or speed control of rotary actuators. Typical application include regulating cutting tool
speeds, spindle speeds, surface grinder speeds, and the travel rate of vertically supported loads moved upward and
downward by forklifts, and dump lifts.
10.3.1 Non-pressure-compensated valves
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. The disadvantage of these valves is that the flow rate depends on the work load. Hence,
the speed of the piston cannot be defined accurately using non-pressure-compensated flow-control valves when the
working load varies. Schematic diagram of non-pressure-compensated needle-type flow-control valve is shown in Fig.
10.14. It is the simplest type of flow-control valve. 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.

. (a) Fully closed; (b) partially opened; (c) fully opened.

(d) Shape of non-compensated flow control valves

 Figure 10.14 Non-pressure-compensated flow control valve

10.3.2 Pressure-compensated valves

Pressure-compensated flow-control valves overcome the difficulty caused by non-pressure-compensated valves by
changing the size of the orifice in relation to the changes in the system pressure. This is accomplished through a spring-
loaded compensator spool that reduces the size of the orifice when pressure drop increases. Once the valve is set, the
pressure compensator acts to keep the pressure drop nearly constant. It works on a kind of feedback mechanism from
the outlet pressure. This keeps the flow through the orifice nearly constant. Schematic diagram of a pressure
compensated flow-control valve is shown in Fig. 10.15. A pressure-compensated flow-control valve consists of a main
spool and a compensator spool. The adjustment knob controls the main spool’s position, which controls the orifice
size at the outlet. The upstream pressure is delivered to the valve by the pilot line A. Similarly, the downstream pressure
is ported to the right side of the compensator spool through the pilot line B. The compensator spring biases the spool
so that it tends toward the fully open position. If the pressure drop across the valve increases, that is, the upstream
pressure increases relative to the downstream pressure, the compensator spool moves to the right against the force of
the spring. This reduces the flow that in turn reduces the pressure drop and tries to attain an equilibrium position as
far as the flow is concerned. Thus, a fixed differential across the control orifice is maintained at all times.

(a-1) Operation of pressure-compensated valve and symbol

 (a-2) Operation of pressure-compensated valve and symbol

(c) Shape of pressure sequence valve

ㅍ

(c) Application circuit of piston speed control (only for extended motion)

Figure 10.15 Operation and application of pressure compensated flow control valve
Question & Answer
Q10.1 Determine true or false for the following statements.
1. Pressure control valves protect the system against overpressure, which may occur due to a sudden surge.
2. A pilot-operated check valve always permits flow in one direction only.
3. A shuttle valve allows two alternate flow sources to be connected in a one-branch circuit.
4. In 4/3 DCV with tandem neutral, the pump flow is allowed to flow to the system.
5. The purpose of the regenerative neutral is that instead of sending the return flow back to the tank, it sends it into
the inlet side of the cylinder, thereby decreasing its speed.

Figure Q10.1-5 Application of 4/3-way valve - regenerative neutral

A10.1 1. True, 2. False, 3. True, 4. False, 5. False(increasing its speed)

Q10.2 Choose a correct word in the parenthesis

1. A valve is a device that receives an external signal to release, (accelerate, stop) the fluid that flows through it.
2. DCVs determine (path, flow) through which a fluid transverses a given circuit.
3. A check valve allows flow in (only one direction, mostly one direction), but blocks the flow in the opposite
direction.
4. In 4/3 DCV with (open neutral, closed neutral) the pump line is blocked so that the flow must pass over the
pressure relief valve the pressure is at the system maximum.
5. In 4/3 DCV with float neutral, the (pressure port, control port) is blocked and the outlet is connected to the tank.
6. In 4/3 DCV with open neutral, the pressure port and the outlets are both connected to the (pump, tank).
A10.2 1. Stop, 2. Path, 3. only one direction, 4. closed neutral, 5. pressure port, 6. tank

Q10.3 A cylinder with a piston diameter of 7cm and a rod diameter of 3.125cm is to be used in a system with a 45lpm
pump. Use the graph in the following figure to determine the pressure drops across the DCV when the cylinder is
retracting (P→B, A→T)
 Figure Q10.3 Relationship between pressure drop and flow in DCV
A10.3 The flow from P to B is the pump flow into the rod end, so this can be read from the graph
∆𝑝 = 3.2bar (approx.)
The flow from A→T is the return flow out of the blind end. This flow rate is greater than the pump flow and must be
determined by the following method:
𝜋 𝜋
(a) Piston area: 𝐴𝑝 = 𝐷𝑝2 = (72 ) = 38.5cm2
4 4
𝜋 𝜋
(b) Rod area: 𝐴𝑟 = 𝐷2 = (3.1252 ) = 7.7cm2
4 𝑟 4
𝑄𝑝𝑢𝑚𝑝 45
(c) Return flow: 𝑄𝑟𝑒𝑡𝑢𝑟𝑛 = 𝐴𝑝 𝑣 = 𝐴𝑝 = (38.5) ( ) = 56.25 lpm
𝐴𝑝 −𝐴𝑟 38.5−7.7

The flow from A to T can now be read from the graph

∆𝑝 = 6.2bar (approx.)

Q10.4 Determine true or false for the following statements.

1. Pressure-relief valves limit the maximum pressure in a hydraulic circuit by providing an alternate path for fluid
flow when the pressure reaches a preset level.
2. A pilot-operated pressure-relief valve cannot be operated using a remote.
3. A common application of an unloading valve is in high–low pump circuits and punching press.
4. Sequence valves are similar to pressure-relief valves.
5. An unloading valve requires electric signals.
A10.4 1. True, 2. False, 3. True, 4. True, 5. False

Q10.5 Choose a correct word in the parenthesis

1. A relief valve is similar to a (fuse, switch) in an electrical system.
2. A pilot-operated pressure relief valve consists of a small (pilot relief valve, pilot check valve) and a main relief
valve.
3. (Counter balance valve, Pressure reducing valve) is used to maintain reduced pressures in specified locations of
 hydraulic systems.
4. (Unloading valve, Counter balance valve) is used to maintain a back pressure on a vertical cylinder to prevent it
from falling due to gravity.
5. A pilot-operated unloading relief valve is the same as a pilot-operated relief valve with the addition of an
(sequence, unloading) spool.
A10.5 1. Fuse, 2. pilot relief valve, 3. Pressure reducing valve, 4. Counter balance valve, 5. Unloading

Q10.6 A pressure-relief valve has a pressure setting of 140bar. Compute the kW loss across this valve if it returns all
the flow back to the tank from a 0.0016m3/s.
A10.6 We have power loss = 𝑝𝑄 = (140 × 105 N/m2 )(0.0016m3 /s)=22400W=22.4kW

Q10.7 A pressure-relief valve contains a poppet with an area of 4.2cm2 on which the system pressure acts. During
assembly, a spring with a spring constant of 3200N/cm is installed in the valve to hold the poppet against its seat. The
adjustment mechanism is then set so that the spring is initially compressed to 0.5cm from its free-length condition. In
order to pass full pump flow through the valve at the pressure-relief valve pressure setting, the poppet must move 0.30
cm from its fully closed position.
(a) Determine the cracking pressure.
(b) Determine the full pump flow pressure(pressure-relief valve pressure setting).
(c) What should be the initial compression of the spring in pressure-relief valve if the full pump flow is to be 40%
greater than the cracking pressure?
A10.7
(a) Cracking pressure
Force required to fully close is the product of initial displacement and spring constant
𝐹𝑖 = 𝐾∆𝑥𝑖 = (3200N/cm)(0.5cm)=1600N
Now we can calculate the cracking pressure knowing the cracking force
𝐹𝑖 = 𝑝𝑐𝑟𝑎𝑐𝑘𝑖𝑛𝑔 𝐴𝑝𝑜𝑝𝑝𝑒𝑡
𝐹𝑖 1600N
∴ 𝑝𝑐𝑟𝑎𝑐𝑘𝑖𝑛𝑔 = = = 381N/cm2 = 38.1bar
𝐴𝑝𝑜𝑝𝑝𝑒𝑡 4.2cm2
(b) Full pump flow pressure
Force required to fully open is the product of final displacement and spring constant
𝐹𝑓 = 𝐾(∆𝑥𝑖 + ∆𝑥𝑠 ) = (3200N/cm)(0.5+0.3cm)=2560N
Now this force must be equal to product of full pump pressure and area of poppet.
𝐹𝑓 2560N
𝑝𝑓𝑢𝑙𝑙 𝑝𝑢𝑚𝑝 𝑓𝑙𝑜𝑤 = = = 609.5N/cm2 = 60.95bar
𝐴𝑝𝑜𝑝𝑝𝑒𝑡 4.2cm2
(c) Let 𝑙 be the initial compression of spring
 𝐹𝑖 = 𝐾𝑙 = 3200𝑙
Now cracking pressure can be calculated as follows
𝐹𝑖 3200𝑙
𝑝𝑐𝑟𝑎𝑐𝑘𝑖𝑛𝑔 = = = 762𝑙
𝐴𝑝𝑜𝑝𝑝𝑒𝑡 4.2cm2
Also we know that force required to fully open is given by product of full pump flow and area of poppet.
𝐹𝑓 = 𝐾(𝑙 + ∆𝑥𝑠 ) = (3200N/cm)(𝑙+0.3cm)=3200𝑙 + 960N
𝐹𝑓 3200𝑙 + 960
𝑝𝑓𝑢𝑙𝑙 𝑝𝑢𝑚𝑝 𝑓𝑙𝑜𝑤 = = = 1.4𝑝𝑐𝑟𝑎𝑐𝑘𝑖𝑛𝑔 = 1066.8𝑙
𝐴𝑝𝑜𝑝𝑝𝑒𝑡 4.2cm2
960
Solving, we get 𝑙 = = 0.75cm
1066.8∗4.2−3200

Q10.8 Determine true or false for the following statements.

1. The speed of a piston can be defined accurately using non-pressure-compensated flow-control valves when the
working load varies.
2. Speed control by controlling the rate of flow out of the cylinder is called meter-in control.
3. In a meter-in circuit, the extending speed of the cylinder is controlled whereas the retracting speed is not.
4. Compared to the meter-in and meter-out circuits, the bleed-off circuit is more commonly used.
5. In a meter-in circuit, flow coming from the pump into the cylinder is not controlled directly.
However, the flow out of the cylinder is controlled using a flow-control valve
A10.8 1. False, 2. False, 3. True, 4. False, 5. False

Q10.9 Choose correct word in the parenthesis

1. Non-pressure-compensated flow-control valves are used when the system pressure is relatively (high, constant)
and motoring speeds are not too critical.
2. A pressure compensator acts to keep the (flow, pressure drop) nearly constant.
3. In (pressure compensated, constant pressure drop) flow-control valve consists of a main spool and a compensator
spool.
4. Speed control by controlling the rate of flow (into, out of) the cylinder is called meter-in control.
5. In a meter-(in, in or out) circuit, only the speed during the extend stroke is controlled.
A10.9 1. Constant, 2. pressure drop, 3. pressure compensated, 4. Into, 5. in or out

Q10.10 The system shown in the following figure has a hydraulic cylinder with a suspended load W. The cylinder
piston and rod diameters are 50.8 and 25.4mm, respectively. The pressure-relief valve setting is 5150kPa. Determine
the pressure p2 for a constant cylinder speed:
(a) W=8890 N
(b) W=0(load is removed)
 (c) Determine the cylinder speeds for parts (a) and (b) if the flow-control valve has a capacity coefficient of 0.72 ∗

lpm/√kPa. The fluid is hydraulic oil with a specific gravity of 0.90.

Figure Q10.10
A10.10 For a constant cylinder speed, the summation of the forces on the hydraulic cylinder must be equal to zero.
Thus, we have
−𝑊 − 𝑝1 𝐴𝑝 + 𝑝2 (𝐴𝑝 − 𝐴𝑟 ) = 0, where 𝑝1 =pressure relief valve setting=5150kPa.
𝜋 𝜋
Now, 𝐴𝑝 = 𝐷𝑝2 = (0.05082 ) = 0.00203m2
4 4
𝜋 𝜋
𝐴𝑟 = 𝐷𝑟2 = (0.02542 ) = 0.000506m2
4 4
So, 𝐴𝑝 − 𝐴𝑟 = 0.00152m2
(a) If W=8890N
−𝑊 − 𝑝1 𝐴𝑝 + 𝑝2 (𝐴𝑝 − 𝐴𝑟 ) = 0
8890 − (5150 × 103 )(2.03 × 10−3 ) + 𝑝2 (0.00152) = 0
𝑝2 = 12700kPa
(b) If W=0N
−𝑊 − 𝑝1 𝐴𝑝 + 𝑝2 (𝐴𝑝 − 𝐴𝑟 ) = 0

0 − (5150 × 103 )(2.03 × 10−3 ) + 𝑝2 (0.00152) = 0

𝑝2 = 6880kPa
(c-1) Cylinder speed for (a):
∆𝑝 12700
For a sharp-edged orifice, we can write 𝑄 = 𝐶𝑣 √ = 0.72√ = 85.5 lpm,
SG 0.9

where ∆𝑝 = 𝑝2 because the flow-control valve discharges directly to the oil tank.
This is the flow rate through the flow-control valve and thus the flow rate of the fluid leaving the hydraulic
cylinder.
Thus, we have
𝑣𝑝 (𝐴𝑝 − 𝐴𝑟 ) = 𝑄
 𝑄 85.5/60000m3 /s
𝑣𝑝 = = = 0.938m/s
𝐴𝑝 − 𝐴𝑟 0.00152m2
(c-2) Cylinder speed for (b):

∆𝑝 6880
𝑄 = 𝐶𝑣 √ = 0.72√ = 63 lpm
SG 0.9

𝑄 63/60000m3 /s
𝑣𝑝 = = = 0.691m/s
𝐴𝑝 − 𝐴𝑟 0.00152m2