Module 3: Components And Hydraulic Circuit Design
Components: Introduction to Hydraulic Components, Classification of Control Valves,
Symbolic Representation, Constructional Features of Directional Control Valves, Flow Control
Valves and Pressure Control Valves.
Hydraulic Circuit Design: Introduction to circuit Design, Control of Single and Double -
Acting Hydraulic Cylinder, Regenerative Circuit, Pump Unloading Circuit, Counter Balance
Valve Application, Hydraulic Cylinder Sequencing Circuits, Hydraulic Circuit for Force
Multiplication; Speed Control of Hydraulic Cylinder- Metering In, Metering Out and Bleed
off Circuits. Pilot Pressure Operated Circuits.
Hydraulic Circuit Design: Control of single and Double -acting hydraulic cylinder,
regenerative circuit, pump unloading circuit, counter balance valve application, hydraulic
cylinder sequencing circuits, hydraulic circuit for force multiplication; speed control of
hydraulic cylinder-metering in, metering out and bleed off circuits. Pilot pressure operated
circuits.
Valve Representation
Direction Control Valve (DCV)
The direction control valves determine the path through which fluid traverses in a given
circuit.
Terminology and symbols associated with valves
Port
Position
Way
2/2 Valve
4/3 Valve 2/2 Valve 5/3 Valve
4 ports and 3 positions
5/2 Valve
Naming of ports:
3/2-way valve: 3ports and 2 position DCV
Classification of DCV
1. According to type of construction
Poppet Valve
Spool Valve
2. According to number of working ports
Two way valve
Three way valve
Four way valve
3. According to number of switching positions
Two position valve
Three position valve
4. According to Actuating mechanism
Mechanical actuation
Manual actuation
Solenoid actuation
Hydraulic actuation
Pneumatic actuation
5. According to control method
Direct controlled DCV
Indirect controlled DCV
Actuating Devices
Check Valve:
The simplest DCV is a check valve. A check valve allows flow in one direction, but
blocks the flow in the opposite direction. Figure shows the graphical symbol of a check valve
along with its no-flow and free-flow directions.
Poppet Check Valve
Sliding Spool Valve:
A spool is a step machined cylinder member, having 2 or 3 lands. The lands are
machined to close dimensional tolerances and will have a sliding fit in the bore of the valve body.
The openings formed between the lands on the spool act as the flow passages between the
connecting ports.
Shuttle Valve
3/2 Spool valve
4/2 Spool Valve:
Pressure Control Valve
PCV are normally used to perform the following functions:
1. Limit the maximum system pressure
2. Regulate/ Reducing pressure in certain portions of circuit
3. Unloading system pressure
4. Assisting sequential operation of actuators
5. Reducing or stepping down pressure levels
Types of Pressure Control Valves
1. Pressure relief valve
2. Pressure reducing valve
3. Unloading valve
4. Counterbalance valve
5. Pressure-sequence valve
Pressure Relief Valve:
1. Simple Pressure Relief Valve
Pressure Relief Valve:
2. Compound Pressure Relief Valve
(Pilot Operated Pressure Relief Valve)
Pressure Reducing Valve
Unloading Valve
Counter Balance Valve
Pressure Sequence Valve
Flow Control Valves (FCV)
FCV control the rate of flow a fluid through a hydraulic circuit.
FCV lifts the fluid volume rate from fixed displacement pump to branch circuits.
Their function is to provide velocity control of linear actuators or speed control of
rotary actuators.
Functions
1. Regulate the speed of linear and rotary actuators.
2. Regulate the power available to the sub circuits by controlling flow.
3. Proportionally divide or regulate the pump flow to various branches of the
circuits.
Classification of Flow Control Valves
1. Non – Pressure Compensated
2. Pressure Compensated
Non Pressure compensated valves are used when the system pressure is
relatively constant and motor speeds are not too critical.
In these types of valves, flow rate through an orifice depends on the pressure
droop across the system or the outlet.
Since inlet pressure is kept constant, the outlet pressure acts directly on the
orifice.
Types of Non – Pressure Compensated Valves
1. Needle Valve
Types of Non – Pressure Compensated Valves
2. Butterfly Valve
3. Ball Valve
Pressure Compensated Valves
Pressure and Temperature Compensated Valves
Hydraulic Control Systems
These are used to control the speed and position of the load with a driving from
a linear or rotary actuator.
Hydraulic control system consists of :
1. Hydraulic power pack – Pump, Motor, Reservoir, Filter Cooler etc
2. Hydraulic control elements – DCV, FCV, PCV, Servo Valves, Actuators. Etc
3. Power Drives – Cylinders, Motors
4. System Accessories – Pipes, Hoses, Accumulators. etc
Hydraulic Circuit
A Hydraulic Circuit is a group of components such as pumps, actuators, Control
valves, conductors and fitting arranged to perform useful work.
It gives us an idea about how these components are interconnected.
The three important considerations to be while designing:
1. Safety of machine and personnel in the event of power failures.
2. Performance of given operation with minimum losses.
3. Cost of the component used in the circuit.
Control of Single Acting Hydraulic Circuit
P T
Control of Double Acting Hydraulic Circuit
Regenerative Cylinder Circuit
Qr
QT
Qp
Load Carrying Capacity During Extension
1. Spring Centered position gives
Rapid advance (Extension)
2. Left envelop gives slow feed
3. Right envelop retracts the piston
Example: Drilling Machine Operation
Sequence Circuit
Sequence Circuit Example 1
Drilling
Step B – Extend Cylinder B B
Step C – Retract Cylinder B
Step A – Extend Cylinder A
Step D – Retract Cylinder A
Sequence Circuit Example 2
Cylinders in Parallel
Cylinders in Series
Speed Control of Hydraulic Cylinder
Meter In Meter OUT
Counterbalance Valve in Circuit
1. Lowering
2. Lifting
3. Suspension
Pump Unloading Circuit
Double Pump Hydraulic Circuit
Automatic Cylinder Reciprocating Circuit
Locked Cylinders With Pilot Check Valve
Pressure Intensifier Circuit
Flow Equalizer Circuit
Fail Safe Circuit
Hydraulic Motor Braking System
Accumulator as an Auxiliary Power Source
Accumulator as an Emergency Power Source
Accumulator as an Hydraulic Shock Absorber
Accumulator as a Leakage Compensator