Industrial Hydraulic Circuits

Industrial Hydraulic circuits
www.automationforum.co
Control Valves
In fluid power, controlling elements are called valves.
There are three types of valves:

1. Directional control valves (DCVs): They determine the
path through which a fluid transverses a given circuit.
2. Pressure control valves: They protect the system against

over pressure, which may occur due to a sudden surge
as valves open or close or due to an increase in fluid
demand.
3. Flow control valves: Shock absorbers are hydraulic

devices designed to smooth out pressure surges and to
dampen hydraulic shock.
DCVs:
A valve is a device that receives an external signal
(mechanical, fluid pilot signal, electrical or electronics) to
release, stop or redirect the fluid that flows through it.
The function of a DCV is to control the direction of fluid flow

in any hydraulic system. A DCV does this by changing the
position of internal movable parts
Classification of DCVs:
Based on fluid path, DCVs can be classified as
follows:
1. Check valves.
2. Shuttle valves.
3. Two-way valves.
4. Three-way valves.
5. Four-way valves.
Check valves:
➢allows flow in one direction, but blocks the flow in the opposite direction.
➢two-way valve because it contains two ports.
Ball-type check valve.
Shuttle valves
allows two alternate flow sources to be connected in a one-branch
circuit.
2/2-Way DCV
A pair of two-way valves is used to fill and drain a vessel.
3/2-Way DCV
4/2 DCV.
PRESSURE-CONTROL VALVES
PCV used in hydraulic systems to control actuator force (force
= pressure × area) and to determine and select pressure levels
at which certain machine operations must occur.
Functions:
1. Limiting maximum system pressure at a safe level.
2. Regulating/reducing pressure in certain portions of the
circuit.
3. Unloading system pressure.
4. Assisting sequential operation of actuators in a circuit
with pressure control.
5. Any other pressure-related function by virtue of pressure
control.
6. Reducing or stepping down pressure levels from the main
circuit to a lower pressure in a sub-circuit.
Valves used for pressure control:
1.Pressure-relief valve.
2.Pressure-reducing valve.
3.Unloading valve
4.Counterbalance valve.
5.Pressure-sequence valve.
Pressure-Relief Valves (PRV)
Functions:
1. PRV limit the maximum pressure in a hydraulic circuit by
providing an alternate path for fluid flow when the
pressure reaches a preset level.
2. All fixed-volume pump circuits require a relief valve to
protect the system from excess pressure.
Simple Pressure-Relief Valve
function is to limit the pressure to a specified maximum value by
diverting pump flow back to the tank.
Advantage of direct-acting relief valves over pilot-
operated relief valves is that they respond very rapidly to
pressure buildup. Because there is only one moving part
in a direct-acting relief valve, it can open rapidly, thus
minimizing pressure spikes.
Compound Pressure Relief Valve(Pilot-Operated Pressure Relief
Valve):
It operates in a two-stage process:
1. The pilot relief valve opens when a preset maximum
pressure is reached.
2. When the pilot relief valve opens, it makes the main
relief valve open.
Pressure-reducing valve
used to maintain reduced pressures in specified locations of hydraulic systems.
Unloading valve:
• used to dump excess fluid to the tank at little or no pressure.
• A common application is in high flow-low pressure pump circuits where
two pumps move an actuator at a high speed and low pressure
• The circuit then shifts to a single pump providing a high pressure to
perform work
Counterbalance valve
•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.
Pressure Sequence Valve
used to force two actuators to operate in sequence
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.
➢ FCV also allow one fixed displacement pump to supply two or

more branch circuits fluid at different flow rates on a priority
basis.
Flow-control valves can be classified as
follows:
1. Non-pressure compensated.
a. Gate FCV
b. Globe FCV
c. Needle FCV
2. Pressure compensated.
Non-pressure-compensated flow-control valves
➢ Usedwhen 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.
Disadvantage-
•The inlet pressure is the pressure from the pump that remains
constant. Therefore, the variation in pressure occurs at the outlet
that is defined by the work load.
•This implies 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.
Non-pressure-compensated flow-control valves: Cont….
Pressure-compensated flow-control valve.
Pressure compensated flow control valves are used to limit or
regulate flow.
➢P3 is conjunction with spring pressure causes downward force and
P2 causes upward force
➢Piston is moves up and down until pressure differential between P2
and P3 matched spring compressive force, hence termed as Pressure-
compensated flow-control valve
Non-pressure-compensated flow-control valves
Gate Valve
➢A valve that opens by lifting a round or rectangular gate/wedge out of the
path of the fluid.
➢The distinct feature of a gate valve is the sealing surfaces between the gate
and seats are planar, so gate valves are often used when a straight-line flow
of fluid and minimum restriction is desired.
➢primarily used to permit or prevent the flow of liquids, but typical gate
valves shouldn't be used for regulating flow, unless they are specifically
designed
for that purpose.
Gatewww.automationforum.co
Valve
Globe valve
➢is a type of valve used for regulating flow in a pipeline, consisting of a
movable disk-type element and a stationary ring seat in a generally
spherical body.
➢Globe valves are used for applications requiring throttling and
frequent operation
➢They are not recommended where full, unobstructed flow is
required.
Globe valve www.automationforum.co
Needle valve
➢A type of valve having a small port and a threaded, needle-shaped
plunger.
➢It allows precise regulation of flow, although it is generally only
capable of relatively low flow rates.
PROPORTIONAL CONTROL VALVES
➢Proportional control valves can be operated easily using a solenoid.
➢ Solenoid controls have a digital control system: A valve is opened

when the solenoid is energized and is closed when it is de-energized or
vice versa.
➢They are very quick in their operation and thus give rise to pressure
and flow surges in the fluid power control units
➢ The advantage of these valves is that they give greater flexibility in

the system design and operation.
➢They also decrease fluid power circuit complexity especially for

processes requiring multiple speed or force outputs.
Notched spool proportional valve.(a) Valve construction;(b) electrical control diagram
Cartridge valves
➢The term cartridge valves commonly refers to pressure,

directional, and flow control valves that screw into a threaded
cavity.
➢These valves are mostly rated for low flows - 40 gpm or less
➢They are available in many configurations; on/off,
proportional, pressure relief, etc. They generally screw into a
valve block and are electrically controlled to provide logic and
automated functions.
Adv:
1. Leakage problem minimum
2. Small size and light in weight
3. Operating noise level is less

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Industrial Hydraulic Circuits

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Industrial Hydraulic circuits

There are three types of valves:

2. Pressure control valves: They protect the system against

3. Flow control valves: Shock absorbers are hydraulic

The function of a DCV is to control the direction of fluid flow

➢two-way valve because it contains two ports.

Ball-type check valve.

•They are used to prevent a load from accelerating uncontrollably.

➢ Their function is to provide velocity control of linear actuators,

➢Typical application include regulating cutting tool speeds,

➢ FCV also allow one fixed displacement pump to supply two or

➢ Solenoid controls have a digital control system: A valve is opened

➢ The advantage of these valves is that they give greater flexibility in

➢They also decrease fluid power circuit complexity especially for

➢The term cartridge valves commonly refers to pressure,

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