Fluid Power Systems/Engineering 2020

Module 3
Components and Hydraulic Circuit Design

 The control of hydraulic power in hydraulic power systems is carried out by means of
control valves. The control requirements are imposed by the function of the system.
 The parameters of the mechanical power delivered to the load are managed hydraulically
by controlling the direction, pressure, and flow rate.
 It is important to know the primary function and operation of the various types of control
components.

Classification of control valves

The selection of control components not only involves the type, but also the size, the actuating
method and remote control capability. There are 3 basic types of valves.
1. Directional control valves (DCV)
2. Pressure control valves (PCV)
3. Flow control valves. (FCV)

Directional control valves (DCV)

As the name implies directional control valves are used to control the direction of the flow in a
hydraulic circuit.
They used to extend, retract or reciprocate hydraulic cylinder and other components for linear
motion
Directional control valves can be classified in a number of ways:
1. According to type of construction:
 Poppet valves
 Spool valves
2. According to number of working ports:
 Two- way valves
 Three — way valves
 Four- way valves

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3. According to number of switching position:

 Two — position
 Three - position
4. Actuating mechanism:
 Manual actuation
 Mechanical actuation
 Solenoid actuation
 Hydraulic actuation
 Pneumatic actuation
5. According to Control method:
 Direct controlled DCV: A valve is actuated directly on the valve spool. This is
suitable for small-sized valves.
 Indirect controlled DCV
 A valve is actuated by a pilot line or using a solenoid or by the combination of
electro-hydraulic and electro-pneumatic means. The use of solenoid reduces the
size of the valve. This is suitable for large-sized valves.
 The designation of the directional control valve refers to the number of working
ports and the number of switching positions. Thus a valve with 2 service ports and
2 switching positions is designated as 2 / 2 way valve.

Constructional features of poppet valves

 Poppet Valves: Directional poppet valves consists of a housing bore in which one or more
suitably formed seating elements ( moveable ) in the form of balls, cones are positioned.
When the operating pressure increases the valve becomes more tightly seated in this
design.
The main advantages of poppet valves are
 No Leakage as it provides absolute sealing.
 Long useful life, as there are no leakages of oil flows.
 May be used with even the highest pressures, as no hydraulic sticking (pressure
dependent deformation) and leakages occurs in the valve.

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The disadvantages of these valves are

 Large pressure losses due to short strokes
 Pressure collapse during switching phase due to negative overlap (connection of
pump, actuator and tank at the same time)

Constructional features sliding spool

 The spool valve consists ofa spool which is a cylindrical member that has large- diameter
lands machined to slide in a very close- fitting bore of the valve body.
 The spool valves are sealed along the clearance between the moving spool and the housing.
The degree of sealing depends on the size of the gap, the viscosity of the fluid and
especially on the level of pressure.
 Especially at high pressures (up to 350 bar) leakage occurs to such a extent that it must be
taken into account when determining the system efficiency.
 The amount of leakage is primarily dependent on the gap between spool and housing.
Hence as the operating pressure increases the gap must be reduced or the length of overlap
increased. The radial clearance is usually less than 20micronsThe grooves between the
lands provide the flow passage between ports.

Check Valve
2/2 DCV Poppet Design

 Figure a Shows a ball poppet type 2 /2 DCV. It is essentially a check valve as it allows free
flow of fluid only in one direction (P to A) as the valve is opened hydraulically and hence
the pump Port P is connected to port A as shown in fig.

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 In the other direction the valve is closed by the ball poppet and hence the flow from the
port A is blocked.
 A poppet is a specially shaped plug element held onto a seat by a spring. Fluid flows
through the valve in the space between the seat and poppet.
 As shown, light spring holds the poppet in the closed position. In the free-flow direction,
the fluid pressure overcomes the spring force at about 35kPa.

Symbol of 2/2 poppet valve

Spool Type Check Valve

 The simplest spool type of directional control valve is a check valve which is a two way
valve because it contains two ports.
 These valves are also called as on-off valves because they allow the fluid flow in only one
direction and the valve is normally closed.
 Two Way valves are available as normally opened or normally closed valves. They are
usually actuated by pilot (Hydraulic actuation) manual, mechanical, solenoid actuated.
 In Fig a) the port P is blocked by the action of spring as the valve is un-actuated (absence of
hand force). Hence the flow from port P to A is blocked. When actuated (Presence of hand
force) the valve is opened, thereby connecting port P to A.

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Pilot operated Check Valve

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Three Way Valve

 Three-way valves either block or allow flow from an inlet to an outlet. They also allow the
outlet to flow back to the tank when the pump is blocked, while a two-way valve does not.
 A three-way valve has three ports, namely, a pressure inlet (P), an outlet to the system (A)
and a return to the tank (T). Generally, these valves are used to operate single- acting
cylinders.

Spool position 1: When the valve is actuated, the spool moves towards left. In this position
flow from pump enters the valve port P and flows out through the port A as shown by the
straight- through line and arrow (fig a). In this position, port T is blocked by the spool.

Spool position 2: when the valve is un-actuated by the absence of hand force, the valve
assumes this position by the action of spring. In this position, port P is blocked by the spool.
Flow from the actuator can go to the tank from A to T as shown by straight through line and
arrow

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Four WayDCV

 These valves are used to operate double

acting cylinder. These valves are also called
as impulse valve as 4/2 DCV has only two
switching positions, i.e. it has no mid
position.
 These valves are used to reciprocate or hold
an actuating cylinder in one position. They
are used on machines where fast
reciprocation cycles are needed. Since the
valve actuator moves such a short distance to
operate the valve from one position to the
other, this design is used for punching,
stamping and for other machines needing
fast action.

Rotary type valves

 Rotary valves consist of a rotating spool which aligns with holes in the valve casing to
give the required operation.
 Figure shows the construction and symbol of a typical valve with center off action.

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 Rotary valves are compact, simple and have low operating forces. They are, however,
low-pressure devices and are consequently mainly used for hand operation in pneumatic
systems

Solenoid actuated valves

 A very common way to actuate a spool valve is by using a solenoid, as illustrated in

figure. As shown, when the electric coil (solenoid) is energized, it creates a magnetic
force that pulls the armature into the coil. This causes the armature push on the push pin
to move the spool of the valve. The solenoid valve has a flow capacity of 45 lpm and a
maximum operating pressure of 250 bar.
 Solenoid-operated valves commonly work at 24 V DC or 110 V AC. A solenoid can
exert a pull or push of about 5-10 kg. This is adequate for most pneumatic spool valves,
but is too low for direct operation of large-capacity hydraulic valves. There are two types
of solenoid designs used to dissipate the heat developed in electric current flowing in the
coil. The first type dissipates the heat into surrounding air and is referred to as an "air gap
solenoid." In the second type "wet pin solenoid," the push pin contains an internal

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passage way that allows the tank port oil to communicate between the housing of the
valve and the housing of the solenoid. Wet pin solenoids do a better job in dissipating
heat because the cool oil represents a good heat sink to absorb heat from the solenoid. As
the oil circulates, the heat is carried into the hydraulic system where it can be easily dealt
with.

Pilot Operated DCV valves

 Directional control valves can also be shifted by applying air pressure against a piston at
either end of the valve spool. Springs (located at both ends of the spool) push against
centering washers to center the spool when no air is applied. When air is introduced
through left end passage, its pressure pushes against the piston to shift the spool to the right.
Removal of this left end air supply and introduction of air through the right end passage
causes the spool to shift to the left. Therefore, this is a four-way, three-position, spring
centered, air pilot-actuated directional control valve.

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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 3.13 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

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Pressure Control Valves

 Hydraulic energy is produced as long as the prime mover drives the pump, and hydraulic
pressure develops by resistance to pump flow. Hence, the hydraulic system suffers damage
if the pump flow is not stopped or unloaded back to the reservoir during non-action periods
of the hydraulic circuit. Non-action periods arise from stalling an actuator, or by reaching
the end of the stroke or the circuit sequence, or during the time-delay periods of the circuit
Sequence.
 In order to avoid hydraulic system damage, power wastage and overheating of the
hydraulic fluid, circuit designers use a variety of cleverly designed systems to control
maximum system pressure and pump flow during non-action periods.

Pressure controls are mainly used to perform the following system functions:
 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.

The valves used for accomplishing the above-mentioned system functions are therefore given
the following names:
1. Pressure-relief valve.
2. Pressure-reducing valve.
3. Unloading valve
4. Counterbalance valve.
5. Pressure-sequence valve.

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Pressure-Relief Valves
 The pressure relief valves are used to protect the hydraulic components from excessive
pressure. This is one of the most important components of a hydraulic system and is
essentially required for safe operation of the system.
 Its primary function is to limit the system pressure within a specified range. It is similar to a
fuse in an electrical system.
 Pressure relief valve is normally a closed type and it opens when the pressure exceeds a
specified maximum value by diverting pump flow back to the tank.
 The simplest type valve contains a poppet held in a seat against the spring force as shown
in Figure. The fluid enters from the opposite side of the poppet. When the system pressure
exceeds the preset value, the poppet lifts and the fluid is escaped through the orifice to the
storage tank directly. It reduces the system pressure and as the pressure reduces to the set
limit again the valve closes.
 Schematic of direct pressure relief valve is shown in figure .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 spring is adjustable 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 reseats as the pressure drops
below the pre-set value.

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Pressure-Reducing Valves

The second type of valve is a pressure-reducing valve. This type of valve (which is normally
open) is used to maintain reduced pressures in specified locations of hydraulic systems. It is
actuated by downstream pressure and tends to close as this pressure reaches the valve setting.
Schematic diagram of pressure reducing valve is shown in Fig

 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. Note that there is an internal passageway from the outlet which transmits
outlet pressure to the spool end opposite the spring.
 When the outlet (downstream) pressure increases to the valve setting, the spool moves to
the right 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 separate drain line to the
tank.

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Fluid Power Systems/Engineering 2020

Unloading Valves

 The construction of unloading valve is shown in Figure. This valve consists of a control
chamber with an adjustable spring which pushes the spool down. The valve has two ports:
one is connected to the tank and another is connected to the pump. The valve is operated by
movement of the spool. Normally, the valve is closed and the tank port is also closed.
 These valves are used to permit a pump to operate at the minimum load. It works on the
same principle as direct control valve that the pump delivery is diverted to the tank when
sufficient pilot pressure is applied to move the spool. The pilot pressure maintains a static
pressure to hold the valve opened. The pilot pressure holds the valve until the pump
delivery is needed in the system. As the pressure is needed in the hydraulic circuit; the pilot
pressure is relaxed and the spool moves down due to the self-weight and the spring force.
Now, the flow is diverted to the hydraulic circuit. The drain is provided to remove the
leaked oil collected in the control chamber to prevent the valve failure. The unloading
valve reduces the heat buildup due to fluid discharge at a preset pressure value.

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 Another application of, pressure unloading valve is sending excess flow from the cap end
of an oversize-rod cylinder to the tank as the cylinder retracts. This makes it possible to use
a smaller, less-expensive directional control valve while keeping pressure drop low.

Counterbalance Valves

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Pressure Sequencing Valves

Schematic of the sequence valve is shown in Figure. Its construction is similar to the direct
relief valve. It consists of the two ports; one main port connecting the main pressure line and
another port (secondary port) is connected to the secondary circuit. The secondary port is
usually closed by the spool. The pressure on the spool works against the spring force. When the
pressure exceeds the preset value of the spring; the spool lifts and the fluid flows from the
primary port to the secondary port. For remote operation; the passage used for the direct
operation is closed and a separate pressure source for the spool operation is provided in the
remote operation mode.

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Flow Control Valves

 Flow-control valves, as the name suggests, control the rate of flow of a fluid through a
hydraulic circuit.
 Flow-control valves accurately limit the fluid volume rate from fixed displacement pump
to or from branch circuits. 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. A very common example to the fluid flow control valve is the
household tap

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. The operating principle behind these valves is
that the flow through an orifice remains constant if the pressure drop across it remains the same.
In other words, the rate of flow through an orifice depends on the pressure drop across it.
 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 workload. 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.

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Needle Valve

 The needle valve is quite commonly used valve. It is also termed as plug valve. Schematic of
Needle or plug valve is shown in Figure.
 This valve has a conical disc which can be adjusted in vertical direction by setting flow
adjustment screw. The adjustment of needle alters the orifice size between plug and valve seat.
Thus the adjustment of plug controls the fluid flow in the pipeline. The characteristics of these
valves can be accurately predetermined by machining the taper of the plug. The typical example
of needle valve is stopcock that is used in laboratory glassware. The valve body is made of glass
or Teflon. The plug can be made of plastic or glass. Special glass stopcocks are made for
vacuum applications.

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Butterfly Valve
 A butterfly valve is shown in Figure 3. It
consists of a disc which can rotate inside
the Pipe. The angle of disc determines
the restriction. Butterfly valve can be
made to any size and widely used to
control the flow of gas. These valves
have many types which have for
different pressure ranges and applications. The resilient butterfly valve uses the flexibility
ofrubber and has the lowest pressure rating. The high performance butterfly valves have a slight
offset in the way the disc is positioned. It increases its sealing ability and decreasesthe wear.
 For high-pressure systems, the triple offset butterfly valve is suitable which makes use of a
metal seat and is therefore able to withstand high pressure. It has higher risk of leakage on the
shut-off position and suffers from the dynamic torque effect. Butterfly valves are favored
because of their lowest cost and lighter weight.

Ball Valve
 The ball valve is shown in Figure. This type of flow control valve uses a ball rotated inside
amachined seat. The ball has a through hole as shown in Figure.
 It has very less leakage in its shut-off condition. These valves are durable and usually work
perfectly for many years. They are excellent choice for shutoff applications. They do not offer
fine control which may be necessary in
throttling applications. These valves are
widely used in industries because of their
versatility, high supporting pressures (up to
1000 bar) and temperatures (up to 250°C).
They are easy to repair and operate.

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Pressure-compensated flow-control valves

 Pressure-compensated flow-control valves overcome the difficulty caused by nonpressure-
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

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Pressure- and temperature-compensated flow control valves : because the viscosity

of hydraulic oil varies with temperature (as do the clearances between a valve's moving parts),
output of a flow-control valve may tend to drift with temperature changes. To offset the effects of
such temperature variations, temperature compensators adjust the control orifice openings to correct
the effects of viscosity changes caused by temperature fluctuations of the fluid, This is done in
combination with adjustments the control orifice forpressure changes as well.

Hydraulic control system

Hydraulic control system is used to control the speed and position of the load with a driving force
which comes from an actuator-either linear or rotary. The main parts which are essentially needed to
design and construct a system may be listed as:

1. Hydraulic power pack comprising of the pump, drive motor, reservoir, filters, coolers
etc.
2. Hydraulic control elements like various types of directional control, pressure control, and
flow control valves, servo valves, actuators, etc.
3. Power drives units comprising of cylinders and motors.
4. System accessories such as pipes, hoses and other fluid conductors, accumulators etc.

Hydraulic designer has to decide not only the type of components to be chosen for the desired
function, but he also has to analyze their mutual compatibility so that the ultimate design is
comprehensive enough in terms of functional efficiency as well as reliability and
maintainability of the constructed system

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