PRESSURE CONTRO VALVES

Hydraulic energy is produced as long as the prime mover (usually an electric motor) drives the
pump, and hydraulic pressure develops by resistance to pump [Link], the hydraulic system
suffers damage if the pump flow is not stopped or off loaded (recirculate) back to the tank
during non-action periods of the circuit.
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.
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.
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.
• Any other pressure-related function by virtue of pressure control.
• Reducing or stepping down pressure levels from the main circuit to a lower pressure in a
sub-circuit.

The most widely used type of pressure control valve is the pressure-relief valve because it is
found in practically every hydraulic system. Schematic diagram of simple relief valve is
shown in Fig. 1.1 and three-dimensional view is shown in Fig. 1.2.
It is normally a closed valve whose function is to limit the pressure to a specified maximum
value by diverting pump flow back to the tank. A poppet is held seated inside the valve by a
heavy spring. When the system pressure reaches a high enough value, the poppet is forced
off its seat. This permits flow through the outlet to the tank as long as this high pressure
level is maintained. Note the external adjusting screw, which varies spring force and, thus,
the pressure at which the valve begins to open (cracking pressure)(Fig. 1.3). It should be
noted that the poppet must open sufficiently to allow full pump flow. The pressure that exists
at full pump flow can be substantially greater than cracking pressure. The pressure at full
pump flow is the pressure level that is specified when referring to the pressure setting of the
valve. It is the maximum pressure level permitted by the relief valve.
Direction Control Valves(DCV)
Directional valves are devices used to change the flow direction of fluid within a hydraulic
circuit. A valve is designed to control the direction of movement of a work cylinder or the
direction of rotation of a fluid motor.
It 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.
PURPOSE OF DCV
• To start, stop, accelerate, decelerate and change the direction of motion of a hydraulic
actuator.
• To permit the free flow from the pump to the reservoir at low pressure when the pump’s
delivery is not needed into the system.
• To vent the relief valve by either electrical or mechanical control. • To isolate certain
branch of a circuit.
Any valve contains ports that are external openings through which a fluid can enter and exit
via connecting pipelines. The number of ports on a DCV is identified using the term “way.”
Thus, a valve with four ports is a four-way valve A DCV consists of a valve body or valve
housing and a valve mechanism usually mounted on a sub-plate. The ports of a sub-plate
are threaded to hold the tube fittings which connect the valve to the fluid conductor lines.
The valve mechanism directs the fluid to selected output ports or stops the fluid from passing
through the valve. DCVs can be classified based on fluid path, design characteristics, control
methods and construction. 1.2.1
Classification of DCVs based Fluid Path Based on fluid path, DCVs can be classified as
follows: • Check valves. • Shuttle valves. • Two-way valves. • Three-way valves. • Four-way
valves.
Classification of DCVs based on the Construction of Internal Moving Parts Based on the
construction of internal moving parts, DCVs can be classified as follows:
• Rotary 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.
• Sliding spool type: This consists of a specially shaped spool and a means of positioning
the spool. The spool is fitted with precision into the body bore through the longitudinal axis
of the valve body. The lands of the spool divide this bore into a series of separate chambers.
Rotary actuators
The actuators convert fluid energy into mechanical energy.
Rotary actuators transform fluid energy into rotational mechanical energy. The
actuators can transmit energy in three different forms(A) high-speed rotational
energy,(B) high-torque rotational energy, or limited-rotation
energy
High-speed motor applications commonly drive components, gear boxes, or shafts at
high speeds, for example 1000 to 5000 rpm. In order to achieve the high speeds, the
motors commonly have smaller displacements.
High-torque motor applications are used to drive components that have high
operating loads, such as a hydrostatic drive system on a dozer. The high-torque
motors commonly use larger displacements and potentially high drive pressures, in
excess of 6000 psi (414 bar).
Limited-rotation actuators rotate less than a full revolution, or just a few rotations.
The actuators use fluid energy to move an object in an arcing motion, but are often
limited to less than 360°
OPERATING PRINCIPLE OF A hydraulic motor: It is a positive-displacement
actuator, containing several oil chambers that receive oil flow for the purpose of
driving an output shaft. The output shaft will rotate when the oil pressure acting on
the motor’s chambers is high enough to overcome the load on the output shaft.
Because hydraulic motors are positive displacement, they generally rotate at a speed
proportional to the input flow.
Hydraulic motor can be designed as UNIDIRECTIONAL(Irreversible), i.e. the motor
is configured to rotate only in one direction, clockwise or anticlockwise.

Other motors designed as bidirectional.

❖ In the industry, the use of pneumatic and hydraulic systems has represented an
efficient solution for automation problems and process control that requires moving
loads and performing sequential operations over the past seven decades.
❖ Pneumatics has become a key technology in industrial automation and is used
in a wide range of applications, such as manufacturing, heavy machinery,
construction, mining, food industry, energy production, and many other areas.
❖ Pneumatic technology has evolved over the years, and today advanced and
sophisticated pneumatic systems are used that allow for greater automation and
efficiency in industrial processes.
❖ Pneumatic sequences are commonly used in industrial automation to drive the
movement of machines or systems. For example.., in a production line, pneumatic
sequences can control the movement of a machine's components to perform a specific
task. They are also used in process automation systems, such as controlling a flow
valve or opening and closing a safety gate.
❖ In general, pneumatic sequences offer a reliable and precise way to control motion
in automated systems and are widely used in a variety of industries, from
manufacturing to the food and pharmaceutical industries.
❖ There are also systematic methods that can represent a general solution to a large
number of problems in pneumatic sequences. One such method is the step-by-step
method.
❖ For the systematic step-by-step method, four fundamental steps are followed: grouping,
identifying conditions or states (end-of-stroke valves) in each phase and group,
identifying valves and components to be used in the implementation, and designing and
simulating the pneumatic circuit. This method is applied to sequences with a minimum
of 3 groups, characterized by using 3/2 directional control valves for switching and
group change.
❖ The cascade method, on the other hand, involves four fundamental steps: grouping,
identifying the conditions or states (such as end-of-stroke valves) in each phase
and group, selecting the appropriate valves and components, and designing-
simulating the pneumatic circuit.

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