Fluid Power Systems (ME353)

Fall 2012
Lecture 8

Controlling the System

Pressure, Direction, and Flow

Primary Control Functions in a

Hydraulic System

 Control valves allow hydraulic systems to produce the type of

motion or level of force needed to complete the functions
expected of a hydraulic circuit
A variety of valves can control actuator direction, speed, and
force output
The three basic types of control valves are:
Pressure control
Directional control
Flow control

 Pressure control valves can:

Protect the system from damage due to excessive pressure
Sequence motion
Limit pressure in selected sections of a circuit

 Directional control valves direct

fluid flow to establish and control
actuator movement

 Flow control valves control the operating speed of actuators

They provide a means to vary the rate of fluid flow

Basic Structure and Features

of Control Valves

 A valve body serves as the holder of the working elements of a valve

Body can be a special casting or machined from standard stock materials
Typical parts of the body include precision bores, ports, and fittings for
mounting

 Fluid control valves incorporate several internal elements to provide a

desired operation
The elements allow, direct, meter, or stop the flow of fluid
The elements include fixed orifices, needle valves, spools, poppets, and
sliding plates
A fixed orifice is a precision hole either:
Machined into the valve body or a component
Pressed as a separate part into a valve passageway
Both designs are used to control fluid flow

 A spool is a cylindrical metal piece fitted into the bore of a

valve body
The spool is used to block or direct fluid through a valve to
produce a desired fluid flow characteristic

 Internal and external forces are used to position the various

valve elements
Springs are typical internal forces used to operate valve
elements
Manual, pilot pressure, and electromagnetic force are
common external forces used for operation
Precision fit, rather than separate seals, is used to prevent
excessive internal leakage in most hydraulic control valves
Internal leakage must be drained from valve chambers
Fluid buildup causes backpressure
Backpressure prevents the proper operation of internal valve
elements

 Internal and external drains are used to remove internal leakage

Internal drains may be used when the outlet line is not subjected to
system pressure
External drains are connected to low-pressure return lines leading to the
reservoir

 Normal valve position refers to the position the internal

elements assume when a hydraulic system is shut down
Normally open
Normally closed
Symbols for normally open and normally closed valves

 Directional control valves may be referred to by the number of

distinct flow positions provided by the valve
Two position
Three position

Valve Operation (Springs, Fluid

Pressure, and Orifice fluid flow):
Springs, fluid pressure, and fluid flow are very important in the operation of
hydraulic system control valves
Springs are used in control valves to:
Move spools and other internal elements
Establish the maximum operating pressure
Serve as a biasing force

 Fluid pressure is used in control valves to:

Directly open or close valves
Remotely operate a valve element
Operate a compensating device to obtain desired fluid flow

Fluid flow through an orifice is used in control valves to establish

differences in pressure
- These pressure differences combined with balancing pistons and biasing
springs are commonly used in the operation of pressure and flow control
valves

Pressure Control Valves

 Pressure control valves may be grouped into one of five types

System maximum pressure control
Actuator sequence control
Restrained movement control
Pump unloading control
Reduced pressure control
Control valves can be classified by internal modes of operation
Direct operation
Balanced-piston operation

 Direct-operated valves depend on heavy internal springs to

establish valve operating pressure

Direct-operated relief valves use system pressure to generate force to

compress a spring
This opens a ball or poppet valve, allowing excess fluid to return to the
reservoir

 Balancing-piston valves (compound relief valves) use lighter

springs and system pressure acting on internal valve
mechanisms to establish the desired operation

Compound relief valves consist of pilot- and balancing-piston sections

Combined into a single valve
More efficient and quieter than direct-operated relief valves

 The pilot section of the compound relief valve contains a small,

direct-operated relief valve
The pilot section indirectly establishes maximum system
pressure by controlling the pressure in the balancing-piston
section of the valve
The balancing-piston section of the compound relief valve uses
a metering orifice and a balancing spring to create pressure and
force differences
These differences correctly position the piston to produce a
desired maximum system operating pressure

 Maximum system pressure control devices are referred to as:

Relief valves
Safety valves
Hydraulic pressure fuses
Relief valves are normally closed valves
They open when system pressure approaches the set maximum
operating pressure
The operation of relief valves can be classified as:
Direct operated
Balancing piston (compound)

 Safety valves are used to prevent damage to the hydraulic

system if the system relief valve should fail to open
Typically, safety valves are direct-operated relief valves
Safety valves are generally set 25% higher than the normal
system operating pressure

 Hydraulic pressure fuses function as a pressure-limiting device by using a

disk that ruptures at a predetermined pressure
They act as a positive-pressure-limiting device for systems where system
pressure limits are critical to safe system operation
A typical hydraulic pressure fuse

 Sequence valves allow the automatic sequencing of two or more actuators in

a hydraulic circuit
Primary actuator moves as soon as fluid flow is directed to the actuator
section of the circuit
Sequence valve blocks flow to the secondary actuator until a
predetermined pressure is reached, then allows fluid flow to the actuator
A sequence valve is typically
fitted with an integral check
valve
This allows free flow of fluid
around the valve when the
direction of the actuator is
reversed
Sequence valve with integral
check valve

 A circuit containing a sequence valve

 Restrained movement control valves are used in circuits to

prevent unexpected actuator movement. Often called:
Counterbalance valves when used with cylinders
Brake valves when used with motors

Counterbalance valves prevent unexpected lowering of the boom

 Counterbalance and brake valves are normally closed valves

A check valve is required to permit free reverse flow around to
valve

Counterbalance valve with integral check valve

 Counterbalance valves allow the downward movement of loads supported

by a cylinder only when the system pump is operating
Force generated by system pressure and the force created by the weight of
the load are needed to move the load downward

Circuit containing a counterbalance valve

 Pump unloading controls hold a desired operating pressure

while the pump operates at near-zero pressure
This reduces energy consumption and maintenance costs
Pump unloading controls use an unloading valve and a dual
pump or accumulator to maintain desired system pressure while
dumping unneeded pump output to the reservoir at very low
pressure

A typical unloading valve

 Unloading valves are normally closed valves with external pilots

Unloading relief valves are used with accumulator circuits
Direct-operated valves can be used in typical high-low dual-pump
circuits
Circuit containing an unloading relief valve