Lab 02 The Application of Pressure Relief Valve and Flow Control Valve v1

FAKULTI KEJURUTERAAN MEKANIKAL
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
HYDRAULIC AND PNEUMATIC
SYSTEMS
LAB 2
DMCF 2232 SEMESTER 1 SESI 2023/2024
LAB 1: The Application of Pressure Relief Valve and Flow Control Valve
DATE : COURSE: [ ] SECTION: [ ] LAB GROUP: [ ]
NAME OF GROUP 1.
MEMBERS &
2.
MATRIX NUMBER
3.
4.
5.
NAME OF 1.
INSTRUCTOR
2.
EXAMINER’S COMMENT VERIFICATION STAMP
TOTAL MARKS
No Dokumen No Isu./Tarikh
TB/MKB/T2/DMCF2232/1 1/09-09-19
HYDRAULIC AND PNEUMATIC SYSTEM
No Semakan/Tarikh Jumlah Mukasurat
The Application of Pressure Relief Valve and Flow
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Control Valve
OBJECTIVES
1. To learn how to install the basic hydraulic components and operate the basic hydraulic system.
2. To understand the applications of pressure relief valve, flow control valve and one -way flow control valve
LEARNING OUTCOMES
At the end of this laboratory session, the student should be able to:
1. Explain the fundamental concept of pressure relief valve, flow control valve and one -way flow control valve.
2. Apply the pressure relief valve, flow control valve and one-way flow control valve at the right position in the
hydraulic circuit.
3. Write a clear and well-presented laboratory report that describes the application of pressure relief valve and
flow control valve in hydraulic circuit.
THEORY
The purpose of a pressure relief valve is to protect a system from too much pressure. This will occur if the actuator is
overloaded or if the flow of fluid is blocked. For example, when a cylinder reaches the end of its stroke, the pump
will still try to pump oil into it but it has nowhere to go. Similarly, if a closed centre valve is used, the pump becomes
blocked off. In such cases the pump or the system will become damaged.
Directional control valves control the direction of flow of the hydraulic fluid and, thus the direction of motion and the
positioning of the working components. Directional control valves may be actuated manually, mechanically, electrically,
pneumatically or hydraulically. They convert and amplify signals (manual, electric or pneumatic) forming an interface
between the power control section and the signal control section.
Flow control valves interact with pressure valves to regulate the flow rate. They make it possible to control or adjust
the speed of motion of the power components. Where the flow rate is constant, division of flow must take place. This is
generally affected through the interaction of the flow control valve with a pressure valve.
(a) (b) (c)
Figure 1 Pressure Relief Valve (a), Flow Control Valve (b), Directional Control Valve (c)
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APPARATUS:
The test rig used in the experiment is DS4 Fluidprax hydraulic trainer from Bosch Rexroth. The apparatus used in this
laboratory session are:
1. Double acting hydraulic cylinder

2. Bi-direction Hydraulic motor
3. Flow control valve (FCV)
4. One-way flow control valve
5. 4/2-way directional control valves spring return
6. 4/3-way directional control valves with detent
7. Pressure relief valve
8. Stopwatch
9. Tachometer
10. Pressure gauge
The detail of schematic diagram is shown in Figure 2.
Figure 2 Hydraulic Circuit
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PROCEDURES
PART A: Flow Control Valve (FCV)
Part A of the experiment is to show the effect of flow control valve on the hydraulic cylinder on both extension and
retraction.
1. Assemble the above hydraulic circuit which includes controlling hydraulic cylinder and motor in one circuit as
shown in Figure 3.
2. Switch on the pump. Set the system pressure to 20 bar by adjusting the pressure relief valve (read the pressure
gauge P1).
3. Fully close the FCV and then open the FCV about 1 turn.
4. Keep pull (left position) the manual lever 4/2-way directional control valves with spring return until fully retract.
Take the time required for the cylinder to fully retract by using stopwatch.
5. Release the manual lever of 4/2-way directional control valves. Use stopwatch to take the time required for
the cylinder to fully extend and record the time in table 1.
6. Repeat procedures 4 to 5 again to get the second reading of time required for the cylinder to fully retract
and extend. Record the time in table 1.
7. Repeat procedures 4 to 6 with increasing the flow rate of hydraulic oil by opening the flow control valve one
turn to complete the data in table1.
8. Measure the length of the cylinder stroke. Record in table 1.
9. Switch of the pump.
Figure 3 Application of flow control valve

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PART B: One Way Flow Control Valve
Part B of the experiment is to show the effect of one-way flow control valve on the rotational speed of the hydraulic
motor, clockwise and anticlockwise as shown in Figure 4.
1. Switch on the pump and let the system pressure maintain at 20 bar (read the pressure gauge P1). If the system
pressure is change, adjust the pressure relief valve setting to 20 bar.
2. Fully close the one-way FCV and then open the one-way FCV about 1 turn.
3. Push (right position) the manual lever of 4/3-way directional control valves with detent so that the motor rotates
clockwise. Take the speed of the motor in rpm by using tachometer.
4. Pull (center position) the manual lever 4/3-way directional control valves to normal position. Pull again (left
position) the manual lever 4/3-way directional control valves so that the motor rotates counterclockwise. Take
the speed of the motor in rpm by using tachometer and record the speed in table 2.
5. Repeat procedures 3 to 4 with increasing the flow rate of oil by opening the one -way FCV one turn (3600) to
complete the data in table 2.
6. Push (center position) the manual lever 4/3-way directional control valves to normal position.
Figure 4 Application of one-way flow control valve
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PART C: Pressure Relief Valve
Based on the schematic of Part A, the experiment of Part C will be furthered to show the effect of pressure relief valve
setting on the hydraulic cylinder on both extension and retraction.
1. Remove the FCV and switch on the pump.

2. Set the system pressure to 10 bar by adjusting the pressure relief valve (read the pressure gauge P1).
3. Keep pull (left position) the manual lever 4/2-way directional control valves with spring return until fully retract.
Take the time required for the cylinder to fully retract by using stopwatch.
4. Release the manual lever of 4/2-way directional control valves. Use stopwatch to take the time required for the
cylinder to fully extend and record the time in table 3.
5. Repeat procedures 3 to 4 again to get the second reading of time required for the cylinder to fully retract and
extend. Record the time in table 3.
6. Repeat procedures 3 to 5 by adjusting the pressure relief valve to 20 bar and 30 bars to complete the data in
table 3.
7. Record the length of the cylinder stroke as measured in Part A into table 3.
EXPERIMENTAL DATA
Table 1 Flow control valve experiment (Part A)

Time (s)
FCV
Reading 1 Reading 2
turning
Retract Extend Retract Extend
1
2
3
Stroke length : _______ m
Table 2 One-way flow control valve experiment (Part B)

One-way Speed (rpm)
FCV Clockwise Counterclockwise
turning
1
2
3
Table 3 Pressure Relief Valve experiment (Part C)

Time (s)
Pressure setting
Reading 1 Reading 2
(bar)
Retract Extend Retract Extend
10
20
30
Stroke length : _______ m
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INSTRUCTION:
Please complete the lab report (informal) in the below section:
PART A: Flow Control Valve (FCV)
TASK 1: DEFINE THE RELATIONSHIPS BETWEEN FCV AND SPEED
TASK 1:
1. Construct a tabulated result to show the average time (s) and speed (m/s) for the cylinder to retract and
extend for each FCV setting.
TASK 1.1: Construct your table here:
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TASK 2: DISCUSSION
Discuss the relationship of FCV setting and the speed of the hydraulic cylinder for extend and retract operation.
TASK 2: Write your discussion here:
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TASK 3: CONCLUSION
State any significant conclusion and suggest any meaningful improvement regarding the experiment, if any.
TASK 3: Write your conclusions here:
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PART B: One Way Flow Control Valve
TASK 1: DEFINE THE RELATIONSHIPS BETWEEN ONE-WAY FCV AND SPEED

1. Plot the graph of motor speed (rpm), against one-way FCV setting (1, 2 and 3 turn) for clockwise and
counterclockwise direction in one graph.
TASK 1.1: Plot your graph here:
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TASK 2: DISCUSSION
Discuss the relationship of one-way FCV setting and the speed of the hydraulic motor for clockwise and
counterclockwise direction. Explain in detail how the one-way FCV works based on this experiment.
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TASK 3: CONCLUSION
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PART C: Pressure Relief Valve
TASK 1: DEFINE THE RELATIONSHIPS BETWEEN PRESSURE RELIEF VALVE AND

SPEED
1. Construct a tabulated result to show the average time (s) and speed (m/s) for the cylinder to retract and
extend for each pressure relief valve setting (system pressure).
2. Plot the graph of hydraulic cylinder speed (m/s) against the system pressure (bar) for extend and retract
operation in one graph.
TASK 1.1: Construct your table here:
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TASK 1.2: Plot your graph here:
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TASK 2: DISCUSSION
Discuss the relationship of system pressure and the speed of the hydraulic cylinder for extend and retract
operation. Discuss the important of pressure relief valve in any hydraulic system.
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TASK 3: CONCLUSION
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Lab 02 The Application of Pressure Relief Valve and Flow Control Valve v1

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FAKULTI KEJURUTERAAN MEKANIKAL

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

HYDRAULIC AND PNEUMATIC

DATE : COURSE: [ ] SECTION: [ ] LAB GROUP: [ ]

EXAMINER’S COMMENT VERIFICATION STAMP

(a) (b) (c)

1. Double acting hydraulic cylinder

The detail of schematic diagram is shown in Figure 2.

Figure 2 Hydraulic Circuit

PART A: Flow Control Valve (FCV)

Figure 3 Application of flow control valve

PART B: One Way Flow Control Valve

Figure 4 Application of one-way flow control valve

PART C: Pressure Relief Valve

1. Remove the FCV and switch on the pump.

Table 1 Flow control valve experiment (Part A)

Table 2 One-way flow control valve experiment (Part B)

Table 3 Pressure Relief Valve experiment (Part C)

Please complete the lab report (informal) in the below section:

PART A: Flow Control Valve (FCV)

TASK 1: DEFINE THE RELATIONSHIPS BETWEEN FCV AND SPEED

TASK 1.1: Construct your table here:

TASK 2: Write your discussion here:

TASK 3: Write your conclusions here:

PART B: One Way Flow Control Valve

TASK 1: DEFINE THE RELATIONSHIPS BETWEEN ONE-WAY FCV AND SPEED

TASK 1.1: Plot your graph here:

TASK 2: Write your discussion here:

TASK 3: Write your conclusions here:

PART C: Pressure Relief Valve

TASK 1: DEFINE THE RELATIONSHIPS BETWEEN PRESSURE RELIEF VALVE AND

TASK 1.1: Construct your table here:

TASK 1.2: Plot your graph here:

TASK 2: Write your discussion here:

TASK 3: Write your conclusions here:

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