Fluid Power Control

FLUID POWER
MODULE:03 ~ HYDRAULIC SYSTEM
COMPONENTS
Sources of Hydraulic Power
Construction and working of pumps – Variable displacement
pumps

Actuators:
Hydraulic cylinders, performing linear motion
Hydraulic motors, performing continuous rotary motion
Hydraulic rotary actuators, performing limited angular

Control Components:
 Pressure Control Valve
 Direction control valve
 Flow control valves
CONTROL
FLUID POWER
COMPONENTS

Pressure Control Valves

 What is a PCV?
CONTROL
FLUID POWER
COMPONENTS

Pressure Control Valves

 Why do we need a PCV in hydraulic circuit?

Limiting maximum system pressure at a safe level.

Regulating/reducing pressure in certain portions of
the circuit.
Unloading system pressure.
Assisting sequential operation of actuators in a
circuit with pressure control.
Reducing or stepping down pressure levels from the
main circuit to a lower pressure in a sub-circuit
CONTROL
FLUID POWER
COMPONENTS

Pressure Control Valves

Types:

Pressure-relief valve.
Pressure-reducing valve.
Unloading valve
Pressure-sequence valve.
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve
 What is a Pressure Relief Valve for?
 Comparison with a fuse in an electrical system.
 Construction and Working Principle.
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve

Spool (1), Housing (2), Spring (3), Spring seat (4), &
Adjusting knob (5).
max
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve
SUMMERY:

 The pressure at which the valve

begins to open is known as
cracking pressure

 The pressure that exists at full

pump flow can be substantially
greater than cracking pressure.

 It is the maximum pressure

level permitted by the relief valve.

 Spring stiffness determines the

difference between full pump flow
pressure and cracking pressure.
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve
Points to note:

 It limits the maximum pressure in a hydraulic circuit by

keeping it below a preset level.
 It provides protection against any overloads; or it limits
the force or torque produced by hydraulic cylinders or
motors.
 It can bypass fluid anytime, or all the time, without
intervention by maintenance.
 A well-designed circuit never bypasses fluid unless there is
a malfunction. This eliminates most overheating problems
and saves energy.
 Note the external adjusting screw varies spring force and,
thus, the pressure at which the valve begins to open (cracking
pressure) also varies.
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve

Graphical Symbol
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve

Symbolic Representation
Typical Hydraulic
of Partial
Power Hydraulic
Pack Circuit
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve

A relief valve is not needed if a pressure-

compensated vane pump is used.
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve

A pressure-relief valve has a pressure

50 bar
setting of 140 bar. Compute the power loss
(kW) across this valve if it returns all the
flow, 0.0016 m3/s, back to the tank from a
pump.

100 bar
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Relief Valve
A pressure-relief valve contains a poppet with an area of 4.2
cm2 on which the system pressure acts. During assembly, a
spring with a spring constant of 3300 N/cm is installed in
the valve to hold the poppet against its seat. The adjustment
50 bar
mechanism is then set so that the spring is initially
compressed to 0.5 cm 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).
100 bar
(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?
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Reducing Valve

50 bar
AWhat
Typical
is a Pressure- Reducing
Hydraulic CircuitValve?
where a pressure
Why is aValve
Reducing Pressure- Reducing Valve
used in a hydraulic system?
is needed.
100 bar
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Reducing Valve

How does it work?

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System.wmv
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Reducing Valve

APPLICATION
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Reducing Valve

Graphica
Symbol
CONTROL COMPONENTS - FLUID POWER
PCV
Pressure-Reducing Valve APPLICATION

Draw a hydraulic circuit for controlling two

double acting cylinders by two separate 4/3
solenoid operated spring centered closed
neutral DCV. Assume actuator -2 will be
operated at reduced pressure.
CONTROL COMPONENTS - FLUID POWER
PCV
Unloading Valve

 Normally
closed type

 Dumps
excess fluid
with little or
no pressure.

 It unloads
the pump.
CONTROL COMPONENTS - FLUID POWER
PCV

Application
of
unloading
valve
in a
punching
press
CONTROL COMPONENTS - FLUID POWER
PCV

Unloading
Valve

Application
of unloading
valve in a
punching
press

(High-Low
circuit)
CONTROL COMPONENTS - FLUID POWER
PCV

Unloading
Valve
CONTROL COMPONENTS - FLUID POWER
PCV
CONTROL COMPONENTS - FLUID POWER
PCV

Operation of
UNLOADING
VALVE

TANK PORT

PILOT PORT

PUMP PORT
CONTROL COMPONENTS - FLUID POWER
PCV

UNLOADING VALVE
With
CHECK VALVE
as an Integral Part
CONTROL COMPONENTS - FLUID POWER
PCV

** APPLICATION OF UNLOADING VALVE **

CONTROL COMPONENTS - FLUID POWER
PCV
CONTROL COMPONENTS - FLUID POWER
PCV

** APPLICATION OF UNLOADING VALVE **

CONTROL COMPONENTS - FLUID POWER
PCV
Unloading Valve ¬ Points to note:

• It allows rapid discharge of pressurized oil near

atmospheric pressure.
• These valves are very reliable and seldom require
maintenance, adjustment or replacement.
• An unloading valve requires no electric signals.
This eliminates the need for maintenance.
• An unloading valve is used to perform operations
such as stamping, coining, punching, piercing, etc.
CONTROL COMPONENTS - FLUID POWER
PCV
Draw a hydraulic circuit to operate one DA cylinder
by a lever operated spring centered 4/3 DCV and, in
addition, to keep pump unloaded in stalled
condition.
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve: Application

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lation(ipad).mp4
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve: Application

A machining operation where the work-piece must be

clamped with a certain force before the cutting tool
starts moving to make contact with the work-piece.
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve:

B
B

P A
P A
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve:

P A
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve: Problems

Think about retraction stroke:

CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve:

P A
P
CONTROL COMPONENTS - FLUID POWER
PCV

P A
P

Sequential Valve
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve:

Application

The Hydraulic Circuit

for a clamp cylinder to
extend first to hold a
work-piece and then a
second cylinder to
extend to bend the
work-piece in the
desired shape.
CONTROL COMPONENTS - FLUID POWER
PCV
Sequential Valve:

Application