2.

Hydraulic Valves, Actuators and

Accessories

24 Marks
 Co related to chapter

• 602.2
Describe working principle of various
components used in hydraulic &
pneumatic systems.
• 602.3
Choose valves, actuators and accessories
required for simple hydraulic and
pneumatic circuits.
 Pressure-control
valves
• Function
Pressure-control valves are 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.
 Types of pressure control
•
valves
Pressure-relief valve.
• Pressure-reducing valve.
• Unloading valve
• Counterbalance valve.
• Pressure-sequence
valve.
 Pressure Relief
valves
• The pressure relief valves are used to
protect the hydraulic components from
excessive pressure.
• It is normally a closed type and it opens
when the pressure exceeds a specified
maximum value by diverting pump flow back
to the tank.
• Schematic of Direct type of relief
direct pressure valve
relief valve is
shown in figure
5.6.1.
• This type of valves
has two ports;
one of which is
connected to the
pump and another
is connected to
the tank.
• It consists of a
spring chamber
where poppet
is placed with
a spring force.
• Generally, the Direct type of relief
spring is adjustable valve
to set the
maximum pressure
limit of the system.
• The poppet is held
in position by
combined effect of
spring force and
dead weight of
spool.
• As the pressure
exceeds this
combined force, the
poppet raises and
excess fluid
bypassed to the
reservoir (tank).
• The poppet again Direct type of relief
reseats as the valve
pressure drops
below the pre-
set value.
• A drain is also
provided in the
control
chamber.
• It sends the fluid
collected due to
small leakage to
the tank and
thereby
prevents the
Three-dimensional view of simple pressure-relief valve.
Compound relief valve or pilot
operated relief valve
Compound relief valve or pilot
operated relief valve
symbo
l

VIDEO
 Pressure Reducing Valve
• Sometimes a part of the system
may need a lower pressure. This
can be made possible by using
pressure reducing valve as
shown in Figure .
• These valves are used to limit
the
outlet pressure.
• Generally, they are used for the
operation of branch circuits
where the pressure may vary
from the main hydraulic
pressure lines.
• These are open type valve
and have a spring chamber
with an adjustable spring, a
movable spool as shown in
• 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.
• When the outlet
(downstream) pressure increases
to the valve setting, the spool
moves to the up to partially
block the outlet port.
• Just enough flow is passed to
the outlet to maintain its preset
pressure level.
• If the valve closes
completely, leakage past the
spool causes downstream
pressure to build up above the
valve setting.
• This is prevented from occurring
because a continuous bleed to
the tank is permitted via a
Three-dimensional view of a
pressure- reducing valve and
symbol

VIDEO
2
 Direction control
valve
• Definition:
• 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.
• Function:
The function of a DCV is to control the
direction of fluid flow in any hydraulic
system.
 Direction control
• Rotaryvalve
spool type: In this type, the spool is
rotated to change the direction of fluid. It
has longitudinal grooves. The rotary spools
are usually manually operated.
VALVE BODY
OUTLET-B
SPOOL

INLET-A
 Direction control
• valve
Sliding spool type:
• In this type, the
spool is slides to
change the direction
A
of fluid.
B
 Check
• The simplest DCV is
a check valve. Valve
• A check valve allows
flow in one direction,
but blocks the flow in
the opposite direction.
• It is a two-way valve
because it contains
two ports.
• Figure 1.1 shows the
graphical symbol of a
check valve along with
its no-flow and free-
flow directions.
 Ball type check
•
valve
In Fig. 1.2, a light spring holds the ball against the valve
seat. Flow coming into the inlet pushes the ball off the
seat against the light force of the spring and continues to
the outlet.
• A very low pressure is required to hold the valve open in
this
direction.
• If the flow tries to enter from the opposite direction, the
pressure pushes the ball against the seat and the flow
cannot pass through.
• VIDE
O
 Poppet check
• Figure 1.3 provides two schematic drawings showing the
operation ofvalve
a poppet check valve. A poppet is a specially
shaped plug element held on a valve seat by a light spring.
Fluid flows through the valve in the space between the
seat and poppet. In the free flow direction, the fluid
pressure overcomes the spring force. If the flow is
attempted in the opposite direction, the fluid pressure
pushes the poppet in the closed position. Therefore, no
flow is permitted
 Pilot-Operated check Valve
• A pilot-operated valve
along with its
symbol is shown in
Fig. 1.4. This type of
check valve always
• permits free flow in
one direction but
permits flow in the
normally blocked
opposite direction
only if the pilot
pressure is applied
at the pilot pressure
point of the valve.
• The check valve
poppet has the pilot
piston attached to the
threaded poppet
stem by a nut.
 Pilot-Operated check Valve
• The light spring holds
the poppet seated in
a no-flow condition
by pushing against
the pilot piston.
• The purpose of the
separate drain port is
to prevent oil from
creating a pressure
build-up at the
bottom of the piston.
• The dashed line in
the graphical symbol
represents the pilot
pressure line
connected to the pilot
pressure port of the
valve. Pilot check
valves are used for
locking hydraulic
cylinders in position.
 Shuttle
• valve
A shuttle valve allows two
alternate flow sources to
be connected in a one-
branch circuit.
• The valve has two inlets P1
and P2 and one outlet A.
Outlet A receives flow
from an inlet that is at a
higher pressure.
• Figure 1.5 shows the
operation of a shuttle valve.
If the pressure at P1 is
greater than that at P2, the
ball slides to the right and
allows P1 to send flow to
outlet A. If the pressure at
P2 is greater than that at
P1, the ball slides to the
left and P2 supplies flow to
outlet A .
 2/2 DIRECTION CONTROL VALVE:

This valve has two ports and two positions of spool. The two ports are inlet
port-A and outlet port-B.

Sliding spool type 2/2 DCV:

The figure shows a sliding spool type

spring return type Normally Closed
2/2DCV. A
In normal position of the spool, the
ports are closed; fluid cannot flow from B
port-A to port-B
When the palm button is pressed,
spool moves to open the passage from
port-A to port-B.

VIDEO
 Rotary spool type 2/2 DCV:

VALVE BODY
OUTLET-B
SPOOL

INLET-A

The figure shows a rotary spool type 2/2DCV.

In first position of the spool, the ports are closed; fluid cannot flow from
port-A to port-B
When the spool is rotated through 90O, it opens the passage from port-A to
port-B,
VIDEO
 3/2 DIRECTION CONTROL VALVE:
This valve is used to operate single acting cylinders. It has three ports
namely, Pump port or inlet port “P”, Cylinder port “A” and Tank port or exhaust
port “T”.
3/2 sliding spool type valve:
The figure shows spring return type sliding spool valve. It has a spring-
loaded spool inside the valve body. In figure, it is palm-operated type of
valve.
A
In spool position as shown in figure,
there is connection from port-A to port-T.
Inlet port port-P is closed.
In spool position as shown in P T
figure, there is connection from port-P to
A
port-A. The tank port or exhaust port,
that is, port-T is closed.

VIDEO P T
 3/2 rotary spool valve:

The figure shows a 3/2 rotary spool valve. It has rotary spool inside the
valve body. The spool is rotated through 120O to operate the valve.

A
valve body
In spool position as shown in figure, there is
connection from P to A. Fluid flows from pump to
single acting cylinder. Hence the
extends. The tank port or exhaust port, that is,
cylinder
port-T is closed. P
T
When the spool is turned to 120O, that is, as spool
shown in shown in figure, there A
from port-A
is to port-T. Fluid flows from single
connection
acting cylinder to tank. Hence the cylinder
retracts. The inlet port port-P is closed.

VIDEO P T
 4/2 DIRECTION CONTROL VALVE:
This valve is used to operate double acting cylinders.
It has four ports namely, Pump port or inlet port “P”, Cylinder port “A”,
Cylinder port “B” and Tank port or exhaust port “T”.

4/2 sliding spool valve:

In spool position as shown in A P B T

figure-A, there is connection from
P to A and B to T. Fluid flows form
pump to port-A and form port-B to
tank.
When the palm button is pressed,
the spool position is as shown in
figure-B, there is connection from A P B T

P to B and A to T. Fluid flows form

pump to port-B and form port-A to
tank.

VIDEO
 4/2 rotary spool valve:

The figure shows a 4/2 rotary spool valve. It has rotary spool inside the
valve body. The spool is rotated through 90O to operate the valve.
T T
valve body

A A
B
B

spool

P P

In spool position as shown in figure-A, there is connection from P to A and

B to T. Fluid flows form pump to port-A and form port-B to tank. Hence the
double acting cylinder extends.
When the spool is turned to 90O, that is, as shown in shown in figure-B,
there is connection from P to B and A to T. Fluid flows form pump to port-B and
form port-A to tank. Hence the double acting cylinder retracts.
VIDEO
 5/2 DIRECTION CONTROL VALVE:
This valve is used to operate double acting cylinders.
It has 5 ports namely, Pump port or inlet port “P”, Cylinder port “A”, Cylinder port
“B” Tank port or exhaust port “T1” and Tank port or exhaust port “T2”.
5/2 sliding spool valve:
In spool position as shown in figure,
A
there is connection from P to A and B to B

T2. Fluid flows form pump to port-A and

form port-B to tank. Hence the double
acting cylinder extends
T1 P T2
When the palm button is pressed, the
spool position is as shown in figure-B,
there is connection from P to B and A to A B
T1. Fluid flows form pump to port-B and
form port-A to tank. Hence the double
acting cylinder retracts.
T1 P T2

VIDEO
 5/2 rotary spool valve:

The figure shows a 5/2 rotary spool valve. It has rotary spool inside the
valve body. The spool is rotated through 72O to operate the valve.
T1
T1 T2 T2
valve body
valve body

B B
A
A
spool spoo
Figure-A Figure-B
P l P
In spool position as shown in figure-A, there is connection from P to A
and B to T2. Fluid flows form pump to port-A and form port-B to tank. Hence
the double acting cylinder extends.
When the spool is turned to 72O, that is, as shown in shown in figure-B,
there is connection from P to B and A to T1. Fluid flows form pump to port-B
and form port-A to tank. Hence the double acting cylinder retracts.

VIDEO
METHODS OF
ACTUATION
METHODS OF
ACTUATION
Types of different center
positions.
 Flow control
• valvevalves, as
Flow-control the name
suggests, control the rate of flow of a
fluid through a hydraulic circuit.
Applications :
• 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.
 Functions of Flow-Control Valves
• Flow-control valves have several functions, some
of which are listed below:
1. Regulate the speed of linear and rotary
actuators: They control the speed of piston that is
dependent on the flow rate and area of the
piston:
2. Regulate the power available to the sub-circuits
by controlling the flow to them:
3. Proportionally divide or regulate the pump flow
to various branches of the circuit: It transfers the
power developed by the main pump to different
sectors of the circuit to manage multiple tasks, if
necessary.
 Classification of Flow-Control Valves

• Flow-control valves can be classified

as follows:
• 1. Non-pressure compensated.
• 2. Pressure compensated.
 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.
• A non-compensated flow control passes
more or less fluid as pressure increases and
decreases.
• This is because more fluid can pass through
a certain size orifice when pressure drop
(pressure difference) across the orifice
increases.
 Non-Pressure-Compensated Valves
• The disadvantage of these valves is discussed below.
• 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.
• This is an extremely important problem to be
addressed in hydraulic circuits where the load
and pressure vary constantly.
Non-pressure-compensated needle-
type flow-control valve
 Non-pressure-compensated needle-
type flow-control valve
• Schematic diagram of non-pressure-compensated
needle-type flow-control valve is shown in Fig.
1.3.
• 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.
 Non-pressure-compensated needle-
type flow-control valve
• Sometimes needle
valves come with an
integrated check valve
for controlling the flow
in one direction only.
• The check valve permits
easy flow in the
opposite direction
without any
restrictions. As shown in
Fig. 1.4, only the flow
from A to B is controlled
using the needle. In the
other direction (B to A),
the check valve permits
unrestricted fluid flow.
 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.
Pressure-Compensated Valves
 Pressure-Compensated Valves
• 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.
• We want to keep
pressure drop (pressure
difference on both side
of knife edge orifice) is
100 to 150 psi.
• The compensator spool
is held open by a 100-
to 150-psi compression
spring that sets pressure
drop across the knife-
edge orifice.
• Flow from the inlet
goes through the
compensating orifice,
past the compensator
spool, and out through
the knife-edge orifice.
• A drilled passage ports
Inlet fluid to the left end
of the compensator
spool, which forces the
spool to the right when
pressure tries to go
above 100 to 150 psi.
• After pressure reaches
or goes above 100 to
150 psi, the
compensator spool
moves to the right and
restricts flow to the
knife-edge orifice flow
control.
• Pressure at the outlet
is ported to the
compression-spring
chamber and increases
the spring force.
• The compensator spool
assures that pressure
drop across the knife-
edge orifice flow control
stays at a constant 100
to 150 psi.
• With a constant pressure
drop, flow stays the
same regardless of inlet
or outlet fluctuations.
 Actuator
• Hydraulic actuators
s are devices used to
convert pressure energy of the fluid into
mechanical energy.

• Depending on the type of actuation,

hydraulic actuators are classified as follows:
• 1. Linear actuator: For linear actuation
(hydraulic cylinders).
• 2. Rotary actuator: For rotary actuation
(hydraulic motor).
• 3. Semi-rotary actuator: For limited angle
of actuation (semi-rotary actuator).
 1.2 Types of Hydraulic
Cylinders
• Hydraulic cylinders are of the following
types:
• Single-acting cylinders.
• Double-acting cylinders.
• Telescopic cylinders.
• Tandem cylinders.
 1.2.1 Single-Acting
Cylinders

• A single-acting cylinder is simplest in design and is shown

schematically in Fig.1.1.
• It consists of a piston inside a cylindrical housing called barrel.
• On one end of the piston there is a rod, which can reciprocate.
• At the opposite end, there is a port for the entrance and exit of oil.
 1.2.1 Single-Acting
Cylinders

• Single-acting cylinders produce force in one direction by hydraulic

pressure acting on the piston.
• (Single-acting cylinders can exert a force in the extending direction
only.)
• The return of the piston is not done hydraulically. In single-acting
cylinders, retraction is done either by gravity or by a spring.
 1.2.2 Double-Acting
Cylinder
• There are two types of double-
acting cylinders:
• Double-acting cylinder with a piston rod
on one side.
• Double-acting cylinder with a piston rod
on both sides.
 Double-Acting Cylinder with a Piston
Rod on One Side

• Figure 1.4 shows the operation of a double-acting cylinder

with a piston rod on one side. To extend the cylinder, the
pump flow is sent to the blank-end port as in Fig. 1.4(a). The
fluid from the rod-end port returns to the reservoir. To
retract the cylinder, the pump flow is sent to the rod-end
port and the fluid from the blank-end port returns to the
tank as in Fig.1.4(b).
Double-Acting Cylinder with a Piston Rod on Both
Sides

A double-acting cylinder with a piston rod on both sides (Fig.1.5)is

a cylinder with a rod extending from both ends. This cylinder can
be used in an application where work can be done by both ends
of the cylinder, thereby making the cylinder more productive.
Double- rod cylinders can withstand higher side loads because
they have an extra bearing, one on each rod, to withstand the
loading.
 1.2.3Telescopic Cylinder
• A telescopic cylinder (shown
in Fig. 1.6) is used when a
long stroke length and a
short retracted length are
required.
• The telescopic cylinder
extends in stages, each stage
consisting of a sleeve that fits
inside the previous stage.
• One application for this type
of cylinder is raising a dump
truck bed.
• Telescopic cylinders are
available in both single-
acting and double-acting
models.
• They are more expensive than
standard cylinders due to
their more complex
construction.
 Telescopic Cylinder
• They generally consist of a nest of tubes
and operate on the displacement
principle.
• The tubes are supported by bearing
rings, the innermost (rear) set of which
have grooves or channels to allow fluid
flow.
• The front bearing assembly on each
section includes seals and wiper rings.
• Stop rings limit the movement of each
section, thus preventing separation. When
the cylinder extends, all the sections move
together until the outer section is
prevented from further extension by its
stop ring.
• The remaining sections continue out-
stroking until the second outermost
section reaches the limit of its stroke; this
 Tandem
cylinder

• A tandem cylinder, shown in Fig. 1.7, is used in

applications where a large amount of force is required
from a small- diameter cylinder.
• Pressure is applied to both pistons, resulting in increased
force
because of the larger area.
• The drawback is that these cylinders must be longer than
a standard cylinder to achieve an equal speed because
flow must go to both pistons.
 Rotary actuators-Hydraulic
motors
• Hydraulic motors are rotary actuators.
However, the name rotary actuator is
reserved for a particular type of unit that is
limited in rotation to less than 360.
• A hydraulic motor is a device which converts
fluid power into rotary power or converts
fluid pressure into torque
Pumps and
motors
Classification of Hydraulic
Motors
• 1. Gear motors.
• 2. Vane motors.
• 3. Piston motors:
A) Axial piston-type motors.
B)Radial piston-type
motors.
Gear
Motors:
 Vane motors-unbalanced
Figure 1.2type
shows an
unbalanced vane motor
consisting of a circular
chamber in which there is an
eccentric rotor carrying several
spring or pressure- loaded
vanes. Because the fluid
flowing through the inlet port
finds more area of vanes
exposed in the upper half of
the motor, it exerts more force
on the upper vanes, and the
rotor turns counterclockwise.
Close tolerances
between the vanes
areand ring The displacement of a vane hydraulic motor is a
maintained
to provide high efficiencies. function of eccentricity. The radial load on the
shaft bearing of an unbalanced vane motor is
also large because all its inlet pressure is on one
side of the rotor.
 Balanced type vane
The radial motor
bearing load problem is
eliminated in this design by using a
double-lobed ring with diametrically
opposite ports. Side force on one side
of bearing is canceled by an equal
and opposite force from the
diametrically opposite pressure port.
The like ports are generally
connected internally so that only one
inlet and one outlet port are brought
outside. The balanced vane-type
motor is reliable open-loop control
motor but has more internal leakage
than piston-type and therefore
generally not used as a servo motor.
 Swash plate piston
motor

In axial piston motors, the piston reciprocates parallel to the axis of the cylinder
block. These motors are available with both fixed-and variable-displacement feature
types.
They generate torque by pressure acting on the ends of pistons reciprocating inside a
cylinder block. Figure 1.4 illustrates the inline design in which the motor, drive shaft
and cylinder block are centered on the same axis. Pressure acting on the ends of the
piston generates a force against an angled swash plate. This causes the cylinder block
to rotate with a torque that is proportional to the area of the pistons. The torque is
also a function of the swash-plate angle. The inline piston motor is designed either as
a fixed- or a variable-displacement unit. The swash plate determines the volumetric
displacement
 Bent axis
A bent-axis pistonmotor
motor is shown in
Fig.1.6. This type of
motor develops torque
due to pressure acting
on the reciprocating
piston. In this motor,
the cylinder block and
drive shaft mount at an
angel to each other so
that the force is
exerted on the drive
shaft flange.
Pipes and Pipe
Fittings
 Necessity of pipes and
•
hoses
In hydraulic system the hydraulic energy is carried by
means of closed conduits/pipes.
• These pipes are designed to carry the high pressure fluid
and to provide flexibility and strength.
• Fluid power lines classified as:
a) Pipe (Rigid)
b) Tubes ( Semi Rigid)
c) Hoses (Flexible)
 Characteristic features of
•
Pipes
They are rigid and suitable for very high pressure
application.
• They are not generally bent.
• Used for permanent application.
• These have maximum strength out off all three pipes.
• These are specified by the nominal bore size and
wall thickness i.e. for a given ID it can have various
OD.
• Pipes are generally made of metals.
 Characteristic features of
•
•
Tubes
They are made of comparatively flexible materials.
They can be bent to any shape and are easy to work.
• It can be used over and over again.
• Tubes are specified based on their outer diameter(OD)
• Tubes are suitable for light weight applications.
 Characteristic features of
• Hoses
Hoses have same strength as pipe.
• Relative movement is possible between the points it
is
connected.
• Easy to install and dismantle.
 Properties of fluid Power
Conduits
• Mechanical strength: It should have sufficient strength
to withstand the subjected pressure.
• Supporting strength: To support the components and
fitting mounted on the piping
• Terminal points: To facilitate dismantling and
assembling
during servicing /repair
• Damping capability: Should dampen out shock waves which
may develop in the system accidentally.
• Smoothness of surfaces: The inner surface of the pipe should
be sufficiently smooth to reduce friction losses.
 Selection of Pipes,Tubes and
Hoses
It is based on
• Required strength in the system
• Pressure needed in the system
• Requirement of flexibility of the actuator
• Availability of materials for maintenance.
• Ease of replacement.
 Pipe
• Steel materials
: Due to Low cost , easy to bend, easy to connect.
For high pressure application
• Copper: Due to high resistance to corrosion.
For low pressure application.
• Aluminium : Light in weight, good resistance to
corrosion. For air craft and missile hydraulic system
• Stainless steel: Corrosion free, Good strength.
Due to high cost
suitable for
particular
application.
 Selection of Pipe
dimension
Three imp. Dimensions of pipes are considered:
• Outside diameter (OD)
• Inside diameter (ID)
• Wall thickness
Pipes are specified by their nominal ID and wall
thickness.
Selection of ID:
• Based on flow rate of fluid
• Permissible frictional losses.
 Schedule of
Pipes
Pipes are classified based on their wall thickness
• Standard pipes
• Extra strong ( Extra heavy)pipes
• Double extra strong ( Double extra heavy ) pipes
The wall thickness is expressed as a schedule number and is
specified by ANSI(American National standard Institute)
Standard: Schedule 40
Extra strong : Schedule 80
Double extra strong :
Slightly thicker than
Schedule 160
For given ID greater the wall thickness
 Tubes and
Tubings
They are semi Rigid.
Tubing size :
• Tubes are designed by its actual OD e.g. 5/8 inch tube means
having and OD of 5/8 inch.
• Tubes are given numbers in increments of 1/16 inch e.g. No. 6
tube means if will have an OD of 6/16 inch.
• Standard pipes and tubes are available between sizes from
1/16 to 2 inch nominal size.
Hose
s
 Construction of
•
Hoses
It is divided into three layers:
a) Inner tube b) reinforcement c) outer covering
a) Inner tube :This is the passage through which the oil would be
flowing.It is made of a suitable hoses material.Selection of ID
of this tube is done as in case of pipes.
b) Reinforcement:
• The inner tube is covered with reinforcement material
to provide sufficient strength to it.
• It is made up of fiber or steel wire braiding.
• Depending on pressure ,two or three layers may be
given.
c) Outer covering :
• To avoid reinforcement from getting damaged by the impact or
sharp objects outer protective cover is given.
• It also covers reinforcement form abrasion,corrosion
nad other damages.