Introduction to Valves

Hydraulic valves provide interface between hydraulic fluid, the control signal and the hydraulic actuators. They are used to control flow rate, the direction of flow and the pressure of the fluid. The control signal may be mechanical, manual, Hydraulic, pneumatic or electrical. The action of the valve may be digital or analogue. In digital action the valve changes from one set position to another. In analogue action the movement of the valve control element is dependent upon the strength or value of the control signal.

A two or three position lever operated D.C valve is an example of digital valve. Relief valve is an example of analogue control valve.

General Functions of Valves

A relief valve is used to regulate maximum pressure in a circuit or part of the circuit. A four-port spool valve may be used to change the direction of rotation of a hydraulic motor. A flow control valve can alter the speed of an actuator by changing the fluid flow rate to or from the actuator.

Pressure Control Valves

A pressure control valve can be used to limit the max pressure (a relief valve) to set a back pressure ( a counterbalance valve) to pass a signal when a certain pressure has been reached (sequence valve) The principal feature of Pressure control valve is hydraulic forces are resisted by a spring. PCV may be grouped as Relief valves Counterbalance valves Pressure sequence valves Pressure reducing valves

The action of a simple pressure control valve is as follows

When the force arising from the pilot pressure is greater than the spring force, the valve spool will move towards the spring until an equilibrium position is obtained where the pilot pressure is just equivalent to the spring force.

As the pilot pressure varies, the spool position will alter to try to maintain the force equilibrium.

The valve spool may be normally open type or normally closed type.

In normally closed type, the valve closes as the pilot pressure increases

spool

spring

pilot

in out

drain

Pressure relief valve Most widely used type of valve, practically found in every hydraulic system It is normally closed type valve Its function is to limit the pressure to a specified max value by diverting pump flow back to the tank It consists of a poppet held seated inside the valve by the force of a compression spring When the system pressure exceeds the set value, the poppet is lifted off its seat This permit the flow through the outlet to the tank External adjusting screw varies the spring force and thus the pressure at which the valve begins to open (known as cracking pressure)

Simple Pressure Relief Valve & Pressure Vs Flow curve

Relief Valves (contd)

The function of relief valve is to set the max pressure in the hydraulic system Relief valves of ball or poppet type have a rapid response to pressure surges typically 25 ms. Pressure flow characteristic is not constant. Poppet or ball tends to hammer on the seat giving rise to relief valve whine; seat damage can occur with resultant leakage and they are best suited for infrequent duty. A variation is guided poppet type relief valve which has the advantage of a direct poppet valve but is more suitable for continuous duty. Guided piston relief valve is shown below. It is quite in operation and best suited for low pressure applications (up to 100 bar It has a high pressure over ride characteristic. The pressure over ride is the difference between the cracking pressure or opening pressure and the pressure drop across the valve when it is passing the max rated flow at the same valve setting.

Guided piston relief valve

The differential piston/ poppet type relief valve shown below is suitable for pressure up to 350 bar. Pressure acts on the differential areas between the poppet and the seat. When the valve operates, a large flow area opens for a relatively small poppet movement. This results in a low-pressure over ride, but the reset pressure may be appreciably lower than the opening pressure.

Area a

Area b Differential poppet relief valve: force to overcome spring = pressure (a b)

Relief Valve selection and pressure setting

Most direct acting valves have high pressure over ride characteristic which make them unsuitable for systems with widely varying flows The reset pressure (the pressure at which open valve closes) must also be considered. This may be about 50% of the opening pressure Response time is most important for specific application. In general two stage valves give good pressure regulation over a wide range of flows with low pr over ride and close tolerances between opening and resetting pressures. Directing acting valves have rapid response times. Poppet types are the most tolerant to fluid contamination and also tend to have less internal leakage than spool type valves, which make them most suitable for high pressure working

Pressure setting Thumb rule is to set the main relief valve in a circuit at 10 to 20% above the max required working pressure taking into account 1. the type of valve 2. its position relative to the actuator and 3. the pressure losses in the system Where there is more than one pressure valve in a circuit, or when used in conjunction with pressure compensated pumps, the controls must not be set too close together as interaction or hunting may result. It is usual to set the pressure of secondary relief valves at a pressure higher than the main relief valve.

Compound pressure relief valve

Operation of compound pressure relief valve

Compound pressure relief valve operates in two stages This valve operates in two stages The pilot stage is located in the upper valve body and contains a pressurelimiting poppet that is held against a seat by an adjusting spring The lower body contains the port connections Diversions of the full pump flow is accomplished by the balanced piston in the lower body Operation In normal operation, the balanced piston is in hydraulic balance Pressure at the inlet port acts under the piston and also on its top because an orifice is drilled through the large land. For pressures less than the valve setting, the piston is held on its seat by a light spring. As soon as pressure reaches the setting of the adjustable spring, the poppet is forced off its seat. This limits the pressure in the upper chamber The restricted flow through the orifice and into the upper chamber results in an increase in pressure in the lower chamber

This causes an unbalance in hydraulic forces, which tends to raise the piston off its seat. When the pressure difference between the upper and lower chambers reaches approx 1.3 bar, the large piston lifts off its seat to permit flow directly to tank If the flow increases through the valve the piston lifts father off its seat. However this compresses only the light spring, and hence very little override occurs.

Counterbalance valve (a) section

(b) circuit

These are relief valves used to setup back pressure in a circuit Frequently employed to counterbalance the loads Here the valve creates a back pressure to prevent the load running away when the cylinder is retracting (i.e. to bypass the counterbalance valve when raising the load). The usual pressure setting is 1.3 times the load induced pressure. A check valve is incorporated in the circuit shown below to allow free flow in reverse direction. Care should be taken when using conventional relief valve. Because at some stage the tank port will be subjected to maximum circuit pressure. The counterbalance valve has an integral check valve A separate drain connection from the spring chamber is unnecessary because the pressure section of the valve is inoperative when the T port is pressurized ( the flow is through check valve) When it is counterbalancing the back pressure at T should be kept to a minimum.

Problem on application of counterbalance valve

Pressure sequence valves Pressure sequence valves sense a change in pressure in the system and transmit a hydraulic signal when the set pressure is reached. These may be of normally closed or open type. They may be used to assure priority hydraulic pressure in one system before another can operate. These have a separate drain from spring chamber. This is because a high pressure may occur in the output port during normal course of action. Should it be internally drained, any pressure in the output port will be reflected back into the spring chamber causing a malfunction. sequence valve may be used as relief valve in any circuit where excessive back pressures are encountered in the return line. The independently drained pilot makes sequence valves insensitive to downstream back pressure.

A normally closed sequence valve with integral reverse-flow check valve is shown below. Fig (b) shows an application which is to sense that a component has been clamped before initiating the next stage in a sequence of operations. When the component is unclamped, the pressure falls and the sequence valve closes. The check valve prevents the signal being trapped and allows it to decay back past the sequence valve poppet.

Normally closed sequence valve with integral reverse-flow check valve and fig(b) clamping application

Circuit breaker or kickdown sequence valve These are two stage sequence valves suitable for high flow rates Valve is normally closed until the pressure setting is reached Main spool remains open fully even if downstream circuit cause the circuit pressure to fall below the control setting. The function of the valve is similar to that of the two-stage relief valve except that once the main spool has lifted, the kickdown jet is connected to the output port. In this condition the input pressure necessary to hold the valve fully open has only to overcome the resistance caused by the secondary circuit pressure and the light spring situated behind the main spool. It remains open even when the secondary circuit pressure is less than the valve set pressure only resetting at a very low value.

Cylinder sequence circuit Direct acting sequence valves are employed in low flow applications such as providing signals to operate d.c. valves or to positively release a brake force before a machine can function. Where the output flow is used to drive cylinders directly, two-stage valves are usually more appropriate. In fig below when dc valve is in the center condition, cylinder A will extend followed by cylinder B. The flow through cylinder B is through sequence valve S1 which will open when the pressure at full bore end of cylinder A has attained a certain value, probably owing to it having been stopped by some external object or at the extremity of its stroke. With the control valve in its cross over condition, cylinder B will retract before cylinder A, with change-over initiated by S2. In circuits where pressure sensing is used to control the cylinder movements it must be noted that sequence valves operate when a specific pressure has been achieved and do not guarantee that the cylinders have completed or reached a particular point in their strokes.

Cylinder sequence circuit

Sequence valve

Unloading Valve This valve is used to permit a pump to build pressure to an adjustable pressure setting and then allow it to discharge oil to the tank at essentially zero pressure as long as pilot pressure is maintained on the valve from a remote source. Hence the pump has essentially no load and is therefore developing a minimum amount of power. This is the case in spite of the fact that the pump is delivering a full pump flow because the pressure is practically zero. This is not the same with pressure relief valve because the pump is delivering full pump flow at the pressure relief valve setting and thus is operating at max power conditions. As long as the force resulting from the pilot pressure is greater than the force set by the control spring, the relief valve will open fully, allowing the main flow to go to tank at low pressure.

Unloading valve

Internal drain Flow is unrestricted

Primary port from pump

closed

Pilot operation from remote connection opens the valve fully when setting is expected by the remote pressure source

Unloading

Accumulator circuit using two-stage un loader valve with integral check valve

Pressure Reducing Valves ( fig next slide)

These are normally open type and are used to maintain reduced pressures in specified locations of hydraulic systems. It is actuated by a downstream pressure and tends to close as this pressure reaches the valve setting. The valve uses a spring loaded spool to control the downstream pressure. If the downstream pressure is below the valve setting, fluid will flow freely form inlet to the outlet. Internal passage from the outlet transmits outlet pressure to the spool end opposite to the spring. Pressure is sensed at the outlet port and fed to the end of the spring-loaded spool. As pressure in the secondary circuit rises, the valve tends to close against the spring pressure. Flow through the small bleed hole in the spool to the spring chamber and drain prevents the valve closing completely, thus averting a pressure build up in the downstream circuit. The action of pressure reducing valve always generates heat energy because of the throttling effect. This heat energy must be taken into consideration when considering their application. Where two separate pressures are continuously required in a circuit, a two pump system may prove a better solution than one using pressure-reducing valves. This will depend up on the flow and pressure required.

Direct acting Pressure reducing Valve

Bleed oil passage

Spring holds valve open

Leakage flow keeps valve slightly open

Application of pressure reducing valve

Pilot Operated Pressure reducing Valve

Pressure reducing valve with internal check valve

Variable restrictor valve These restrict the flow of fluid producing a drop in pressure. They are used to control the speed of cylinders and motors Often they have one way valve in parallel with it so that restriction occurs only in one direction. Pneumatic version is much simpler as it works at low pressures.

Pneumatic version

DC VALVES The dc valve must direct the flow from pump either to port A or to B. The oil exhausted from the cylinder must be directed back to the tank. The number of ports and the number of positions describe such valves The valve shown below is 5/3 way valve

4/2 way direction control valve The basic symbol for a valve is a rectangle to which the connections are drawn. Each position of a valve is represented by a square within a rectangle. Internal connections are shown to the normal position of the valve. Extra boxes show the internal connections for other positions of the valve. Pressure port is designated by P, and reservoir by T, A and B for other ports.

BIS Convention BS2917

If the valve has neutral position such that neither A nor B is connected in that position, then third rectangle is inserted in the middle as shown. There are various ways in which the middle ports can be connected for various reasons. These are 4/3 way valves.

Besides showing internal connections, the valve must also show the valve is actuated. Various actuation methods known are A hand lever operated and pilot return B pilot operated and pilot return C push button operated and spring return D 3 position valve pilot/pilot with spring centering. E solenoid operated and solenoid return F roller operated and spring return

Symbols for directional control valve operators

4/3 way rotary valve, when the element is rotated about its axis, the various ports P, A, B and T are connected as shown.

Various centre positions can be selected to suit the particular application. The pressure drop through the valve depends on the flow rate, the spool type, the flow path, the fluid viscosity and temperature.

Performance curves for various spool types

Figure below shows for one size of valve, typical performance curves giving pressure drops through various flow paths with the spool types shown and with fluid viscosity 36 cSt. Performance curves must be measured at a specific viscosity and temperature. Under most conditions pressure drop will vary directly with the viscosity

Methods of operating DC valves Figure below shows the hydraulic pilot operated valve. The main valve has 6 ports on the base. T, A, P, B, X, Y The main valve is 4/3 with centre ports closed and spring centered. X and Y are pressure and tank connections for the pilot valve which are brought through the main body to the underside. The pilot connections are made via end plates. The pilot valve is likely to be solenoid operated at both sides.

Solenoid operated valve Solenoid is a coil with iron plunger inside it. When the current flows through the coil, the plunger becomes magnetised and tries to move out of the coil. If the spring is used to resist the movement, the distance moved is directly proportional to the current in the coil. Solenoids are used in hydraulic and pneumatic valves to move the valve element.

Direct acting solenoid valve. A direct acting solenoid valve would have a plunger pushing directly on the valve element as shown. This is more common in pneumatic valves.

Modern solenoid valves are pilot operated. A second small electrically operated poppet valve is fitted at the end which lets the oil/air through to the end of the position and so pilot operates them. The valve shown is a pneumatic solenoid/poppet operated and spring return. When solenoid is activated, the valve switches, when solenoid is deactivated, the valve switches back; hence a two position valve.

If it is required for the valve to stay switched when the solenoid is deactivated, then another solenoid is needed at the other end to switch it back as shown Pressure port is numbered 1, servo ports are 2 and 4, exhaust ports are numbered 3 and 5 (pneumatics air to vented to atmosphere)

Flow control valves These valves are used to direct the flow of fluid to the required line. Check valve These allow the flow in one direction and prevents the flow in reverse direction Check valves are available with different spring rates to give particular cracking pressures The cracking pressure is the pressure at which the check valve just opens The rate of flow of fluid is achieved by varying the area of an orifice An orifice is a sudden restriction in the flow path and may be fixed but is generally variable. Ideally it should be of zero length and sharp-edged in which case it will be insensitive to temperature changes in the fluid flowing. The flow through the orifice will vary as the square root of the pressure drop and will be sensitive to viscosity changes.

Variable restrictor valve These restrict the flow of fluid producing a drop in pressure. They are used to control the speed of cylinders and motors Often they have one way valve in parallel with it so that restriction occurs only in one direction. Pneumatic version is much simpler as it works at low pressures.

Pneumatic version

Flow control valves may be Deceleration valve Viscosity or temperature compensated valve Pressure compensated valve Deceleration valve These are a throttle-type valve in which the throttle opening is controlled by a roller or roller lever. The valve may be either normally open or normally closed so that the flow and hence the acceleration or deceleration can be controlled.

Viscosity or temperature compensated valve Viscosity of oil depends on temperature, hence some manufacturers refer to temperature compensation and others to viscosity compensation. The simplest way to eliminate the effect of viscosity is to use a sharp-edged orifice, the flow through which is independent of viscosity. Flow through these valves is load dependent but this can be remedied by the addition of a pressure compensating spool. An alternate method of temperature compensation is to have part of the orifice adjusting mechanism made of a material with a high coefficient of thermal expansion. When the temperature of the fluid increases, a spindle in the mechanism lengthens thus reducing the control orifice opening.

Pressure compensated valve A pressure compensating spool built into a flow control valve maintains a constant pressure drop across the metering orifice independent of changes in supply and load pressure. Fig below is a two port pressure compensated valve Flow rate is set by an adjustable metering orifice 1, which may also be viscosity compensated. In the unoperated condition, the compensating spool 2 is biased fully open by the compensator spring 3. As soon as flows occur, there will be pressure drop across the valve and pressure upstream of the metering orifice tends to close the valve but this is opposed by spring assisted by pressure from downstream of the metering orifice. The compensator spool adopts a balanced position with a consequential pressure drop over the compensating orifice4, formed by the partially closed spool. A rise in supply pressure tends to close the spool and the increased pressure drop across the compensating orifice balances the increase in supply pressure.

If the load pressure rises, the compensating orifice opens, again maintaining the pressure drop over the metering orifice at a set valve. Pressure compensated flow controls must be used when accurate speed control at varying supply or load pressures is required.

Cartridge valve These are forms of poppet valves designed to fit into a manifold block. Just about all types of valves can be designed as cartridge valves to fit into a block specially machined to accept it. In this way a bank of valves may be built into one block. The block might contain directional valves, relief valves, flow dividers, one way valve and so on.

Meter-in and Meter-out circuits

Application of meter-in and meter-out circuit