Introduction

The delivered mechanical power is controlled by

managing flow rate, pressure, and direction.

Control Valves
Ordinary Switching Valves
Proportional Valves
Servo Valves
Digital Valves ~ microprocessors
 Ordinary Switching Valves
Pressure control valves (PCV)
Relief valves
Pressure-reducing valves
Sequence valves
Accumulator charging valves
Directional control valves (DCVs)
Flow control valves (FCV)
Throttle valve
Series pressure-compensated FCV
Parallel pressure-compensated FCV
Flow dividers
Check valves
Direct-operated & pilot-operated
 Valve Control Elements
Poppet valve
Consists of a head (called a
poppet), a spring, and a
seat
During operation, the valve
is either closed (poppet
seated) or opened (poppet
unseated)
Advantages
Low cost, simple
construction, repair, and
maintenance, and negligible
leakage
Disadvantages
Limitation in the number of
ports and poor controllability
 Valve Control Elements
Spool valve (sliding spool)
Spool mounted in a sleeve
Valve is usually axi-symmetric
and its spool slides axially
Advantages
Increased number of control
ports and its greater
controllability
Disadvantages
The increased leakage and high
initial cost
 Valve Control Elements
Spool valve (rotating spool)
Consists of a spool mounted in a sleeve
Spool rotates inside the sleeve
Used in steering systems
 Direct-Acting Relief Valve
Pressure acts on the annular area

When Fh = Fs, valve cracks open

At some pressure level, total flow

bypasses into reservoir
Direct-Acting Relief Valve
 Direct-Acting Relief Valve
PFC = pressure drop across partially-closed flow control valve
P = pressure at the relief valve
To slow the motor, the flow control valve is closed to create enough
pressure at the relief valve to cause it to crack open
For example: 10 GPM is delivered to the motor. The flow control
valve is fully open, and the pressure at the relief valve is 1000 psi.
Use Fig. 3.5 for relief valve characteristics. What pressure drop must
be created at the relief valve to reduce the motor speed to one-half
its current value?
 Circuit Efficiency
Power
P = PQ/1714
P = hydraulic power (hp)
P = pressure (psi)
Q = flow (GPM)

Anytimethereisapressure
dropacrossavalveandno
mechanicalpowerisoutput,
heatisgeneratedandcircuit
efficiencyisreduced.
 Pilot-Operated Relief Valve
Allows the circuit to operate over a
wider pressure range without loss
of fluid
Orifice
Pressure is the same on the top and
bottom of the skirt
No pressure drop across the orifice is
there is negligible flow across it

Pilot
Dart is held in place by a pilot spring
Fluid above the skirt flows to outlet
when the dart is unseated
Fluid from inlet replaces cavity above
skirt, though spool is still held in
position by the main spool spring
Pilot-Operated Relief Valve
 Pilot-Operated Relief Valve
Rabie illustration:
Pilot-Operated Relief Valve
 Pilot-Operated Relief Valve
Left: comparison
Right: Catalogues may flip axes
 Pilot-Operated Relief Valve
Operation: When the 4-way, 3-position DCV is shifted (either
direction), the 3-way, 2-position DCV is simultaneously shifted
What happens?
 Pilot-Operated Relief Valve
Same operation, different configuration
 Pilot-Operated Relief Valve
Operation: High-pressure relief during extension and
low-pressure relief during retraction
Pilot-Operated Relief Valve
 Pilot-Operated Relief Valve
(1) Main poppet, (2) orifice, (3) orifice,
(4) adjustment element, (5) spring, (6) pilot poppet,
(7) housing, (8) channel to return line (T)
 Pilot-Operated Relief Valve
Another design with two separate cartridges for the
main and pilot stages
 Pressure-Reducer
When a subsystem operates at a pressure lower
than that of the main system
Typ.: throttling elements
 Pressure-Reducing Valve
Does not allow pressure downstream to exceed the set
point
For example:
Clamp B is pressure-limited to prevent damage to part
When exceeded the valve partially closes to create an orifice,
reducing downstream pressure

Recallpreviousexample:
 Pressure-Reducing Valve
Another application
Rotary actuator is turning a screw
Limit applied torque, prevent damage to threads

T =torque(lbin)
P =pressure(psi)
Vra =volumedisplacementof
rotaryactuator(in3/rev)
 Reducing / Relieving Valve
Operates like the
pressure-reducing valve
except that it bypasses
fluid to the reservoir

The orifice between inlet

and bypass (to reservoir)
opens as pressure
increases (similar to relief) DirectActing
ReducingValve ReliefValve

Note
Reducing / relieving valve
has internal drain
Reducing valve has
external drain
 Pressure Reducer
If PA is less than set spring pressure: spool shifts
to extreme right position, P is connected to A
If PA is larger (still less than set spring pressure):
Connection P-A is throttled
If PA is equal to spring set pressure: spool lands
separate A from P.
If PA is greater than set spring pressure: connect
ports A-T.
Pressure Reducer
 Pressure Reducer
Flow characteristics of a pressure reducer
for different preset levels
Sequence Valve & Pressure Reducing Valve
Symbols are similar
Sequence: normally closed, sense inlet pressure
Pressure-reducing: normally open, sense outlet pressure
Both are externally drained
Separate line to reservoir
Outlets are not connected to reservoirs
Check valve
Provide free flow in the reverse direction
 Sequence Valve
Ensures that a certain pressure level is reached before
activating a process
Ex: Secure a piece before machining
Sequence Valve (with flow through)
Spool shifts to secondary circuit when the inlet
creates a large enough hydraulic force
 Sequence Valve
(1)Mainhousing
(2)Pilotvalve
(3)Reversefreeflowcheckvalve
(10)directoperatedDCVspooltypeloadedbyspring(8)
Internalpiloting:plug(4.1)isremovedandplug(4.2)is
installed.Thecontrolpressureactsonthespoolthrough
theplunger(5)
Externalpiloting:Line(X)isactive,plug(4.1)isinstalled
andplug(4.2)isremoved
Ifpilotforce<springforce,spoolisshiftedleft.This
closesthespringchamberofthemainvalve(7).Thetwo
sidesofthemainvalveareinterconnectedbytheorifice
(6).Thepressuresattheinputlineandthespring
chamberareequalandthespringactstokeepthemain
valveclosed.
Ifpressureovercomesspringforce,thenspoolshiftsto
theright.Theliquidflowsfromtheinputport(A)tothe
outputport(B)throughtheorifices(6and9),thespool
valve(10)andthepassages(11,12).Thepressure
differencedevelopedacrosstheorifice(6)actsto
displacethemainvalvepoppetupward.Themainvalve Pilotoperatedsequencevalve
opensandconnectstheinletport(A)withtheexitport CourtesyofBoschRexrothAG
(B).Theorifice(9)actsasadampingelement.
 Unloading Valve
Similar to the relief valve, except that the pilot
line is not connected to sense the pressure at
the inlet
a.k.a. accumulator charging valve

Lets look at the function first before looking at its

operation
 Unloading Valve
Accumulator is precharged with a gas
Fluid moves through check valve and fills accumulator
Unloading valve ensures that accumulator loading
pressure is not exceeded
Builds up pressure faster actuation of cylinder (break-out)
Operation with a lower-cost pump (next slide)
The actuator has a 5-second active part and 20-second passive part, meaning
Unloading Valve
flow is needed for 5 seconds and there is a 20-second interval before flow is
needed again. The accumulator (rated at 1000 psi) can supply 924 in3 of oil. If it
supplies this fluid during the active part of the cycle, it must be recharged
during the passive part.
 Unloading Valve
Two features added to pilot operated relief valve (check valve & small piston)
Example: Accumulator rating 1000 psi, pilot spring 975 psi, spool spring 25 psi
Operates similarly as pilot operated relief valve (dart opens at 975 psi)
At 1000 psi flow bypasses to reservoir: (1) The accumulator pressure pushes the piston
(negating pressure on dart), (2) pump is unloaded at 25 psi, (3) check valve closes (due to
accumulator pressure), (4) dart reseats when accumulator is drained (no pressure on piston)
Another explanation
The spool of the pressure
sensor (1) displaces
downward as the
accumulator pressure
increases.
The check valve (3) is
forced to open if the pilot
piston (2) is displaced
downward
Check valve (4) prevents the pressurized oil in the
accumulator from returning to tank
During operation the piston (1) shifts upward eventually
leading to redirection of pump flow to the accumulator
 Unloading Valve
Pressure drops as the accumulator empties &
(simultaneously) pump is building pressure
Curve is a function of the load, the characteristics of the
accumulator, and the characteristics of the pump
 Differential Unloading Valve
Allows the accumulator to partially discharge
before the valve is unvented
Unvented: Piston moves enough for the dart to reseat
Designed at 15% (and other) pressure drop
Meaning the area of the piston is 15% greater than the
projected area of the dart
Result: the accumulator must drop to 848 psi before
the valve is unvented (i.e. dart is seated)
Counterbalance Valve and Brake Valve
Similar symbols
Both: upstream pilot line
Brake: an additional remote pilot line
Definitions
______________:
Resistive Load a load that acts in the opposite
direction to actuator motion
______________:
Over-running Load a load that acts in the same
direction as actuator motion
 Counterbalance Valve
a.k.a. holding valve
Used to prevent weight from falling uncontrollably
Example:
Two-ton platen, Arod = 14.1 in2, 2:1 area ratio
What pressure setting should be used for the counterbalancing
valve?
 Counterbalance & Sequence
How can you tell the difference?

FUNCTION !!!
 Brake Valve
Same function as a counterbalance valve
Has an internal pilot passage and a remote pilot
passage
Example: Spring set at 1000 psi
Opens when internal pilot reaches 1000 psi
Applied to piston, which pushes spool upward
Opens when remote pilot reaches 100 psi
Applied to spool, where Aspool = 10*Apiston
 Brake Valve
Requires 100 psi at motor inlet to keep it open
If motor overruns (or a negative load is applied), pressure drops
below 100 psi and the brake valve closes to throttle (i.e. control
fluid by obstruction) motor discharge
Requires 1000 psi at the direct pilot to open the valve
Will slow the load (slow the overrun motor)
 Leakage
There is always some leakage past the spool and into the
spring cavity
Needs to be drained to function properly
Internally drained
Meaning a passage is machined to connect the cavity with the
outlet
If the valve outlet connects directly with the reservoir
Externally drained
Meaning a separate line connects the cavity to a reservoir
Sometimes a return line can be used (watch for obstructions!)
 Review
Relief Accumulatorcharging PressureReducing Reducing/Relieving

Sequence
Counterbalance (twoway) Sequence Brake

Additionalreference:http://www.hydraulicspneumatics.com/200/FPE/Valves/Article/True/6412/Valves
The stroke of the cylinder (8 in. bore, 5 in. rod diameter) is 18ft. The design
states that the truck must be lowered in 10 min. The counterbalance valve
is a cartridge mounted in an aluminum block known as a line body. Total
mass of the counterbalance valve is 9.4 lbm. The pressure setting of the
valve (inlet pressure) is 2200 psi, and the pressure drop from the outlet to
the reservoir is 50 psi. Use the following assumptions and calculate the
temperature rise of the counterbalance valve during a retraction event.
The valve is mounted on the cylinder. 20% of the total heat generated is
conducted to the cylinder.
40% of the total heat generated is exchanged to the oil as it passes
through the valve
30% of the total heat is convected or radiated to the surrounding
atmosphere during the event.
Specific heat of aluminum is 0.214 Btu/lbm-oF. 1 hp = 2547 Btu/h.
Hint: Remember that hydraulic power is converted to heat energy when
there is a pressure drop and no mechanical work is delivered
 Directional Control Valves
DCVs are used to start, stop, or change the
direction of fluid flow
Specified by the number of connected lines
(ways) and the number of control positions
4/3 DCV has four ways and three positions
Pressure line (P)
Return line (T)
Cylinder lines (A and B)
 Directional Control Valves
Three most common center
configurations for spool-type DCV
Open Center (Float)

Open Center

Closed Center
 DCV Configuration, Ex: A
Check valve isolates the pump
from pressure spikes due to load

Top:
Flow goes directly to reservoir

Bottom:
Both spools activated
simultaneously
Which cylinder moves?
 DCV Configuration, Ex: B
Same valves, different
configuration

Top:
Flow goes directly to reservoir

Bottom:
Describe the actuation
 Poppet-Type DCVs
Three or four ways & two positions
Generally, the direct-operated DCV of poppet type operates at
pressure levels up to 630 bar and flow rates up to 40 L/min
 Spool-Type DCVs
Widely used in DCVs
Spool-Type DCVs
 Spool-Type DCVs

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DCV Configurations

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Controlling a DCV
Mechanical Control

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Fluid Power Control

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Electronic Solenoids

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 Solenoid Operation
A magnetic field is created when an electric field flows
through a wire
If a wire is wound into a coil, the magnetic field is
generated around the coil windings
: magneto-motive force
N: number of turns of coil
i: electric current
 Solenoid Operation
Magnetic field builds up more readily in soft material (iron, steel)
than in air
A C-frame of iron placed around the coil can concentrate the
magnetic field
If a core is placed inside the coil, the magnetic field will be more
intense when the core is in such a position that the C-frame and
core are both within the magnetized field
Solenoid force will develop when the coil is energized
This force will pull the core to its point of equilibrium the mid-
position of the C-frame

DCsolenoid,Courtesyof
BoschRexrothAG
 DC Solenoid
Current develops a magnetic field of fixed polarity
(definite north and south poles)
Safe from burning out if the correct voltage is applied
Solenoid force is a function of
Solenoid design
Current
Core position
 AC Solenoid
Similar function: change in polarity
Recall direction of force in was no dependent on charge
(DC)
Change in electric current magnitude induces an
electromotive force (volts) and eddy currents (electric
current induced when a conductor is exposed to an
alternating magnetic field) in the metallic parts of the
magnetic circuit (mainly the C-frame and core)

ACsolenoid,Courtesyof
BoschRexrothAG
 Solenoid Operation
Wet pin solenoids provide better heat dissipation and
quite operation
At the point of zero current, there is no force acting on
the core, placing it out of equilibrium. A non-zero
current pulls the core back. This movement of the core
creates a noise, buzz
Is eliminated with a shading coil (lags)
 Spool Valves
Classification according to spool land length
Over-lapping (positive)
Zero-lapping (ideal)
Under-lapping (negative)
 Over-Lapping
Spool land length is greater than the valve opening width
Assuming valve throttle area (opening area) is linearly proportional to the valve
opening and neglecting the radial clearance leakage
 Over-Lapping
Assume constant pressure difference across the
restriction
Zero-Lapping
Under-Lapping
 Pressure & Power

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RexrothAG
Pressure & Power
Forces Acting on the Spool
 Forces Acting on the Spool
If the radial clearance is negligible compared to the valve
opening distance, = 69o
(Rabie does not provide a reference or detailed computation)
 Direct-Operated DCV
For low flow rates, flow forces are negligible
The controller can act on the spool directly
For solenoids, increased size is needed at greater
forces (limited to within 100 L/min)
For greater flow, pilot-operated DCVs are used
or direct-operated DCV controlled mechanically

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RexrothAG
 Pilot-Operated DCV
Pilot valve
Direct-operated DCV
(right: controlled
electrically)
Lines could be connected
to external ports

Main valve
Pilot: neutral
Control chambers C & D CourtesyofBosch
RexrothAG
are drained into the tank
and main spool is put in its
neutral position
Solenoid (a) energized
Pilot valve moves right
High pressure oil reaches
D and main spool moves
left
Pilot-Operated DCV
 Check Valves
Allow free flow in one direction, and prevent
(obstruct) the fluid flow in the opposite direction
 Direct-Operated Check Valves

Spring-loaded
Cracking pressure
usually less than 10 bar

Without springs
Cracking pressure less
than 0.2 bar
Pilot-Operated Check Valves
 Pilot-Operated Check Valves
In some operating modes, it is recommended to open
the check valve to allow free flow
Without External Drain Ports
When pressure is applied to the port (X) the pilot piston (4)
moves to the right. The decompression poppet (5) opens first,
followed by the main poppet (2). This design permits the rapid
and smoot decompression of the fluid

1. Valvehousing
2. Mainpoppet
3. Spring
4. Pilotpiston
5. Decompressionpoppet
X.Pressuresupplyport

CourtesyofBosch
RexrothAG
 Pilot-Operated Check Valves
With External Drain Ports
An additional external drain port (Y) allows the annulus area of
the pilot piston (4) to be drained separately. The pressure at the
port (A) only acts on the rod area of the pilot piston (9), which
reduces the influence of downstream pressure

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RexrothAG
Double Pilot-Operated Check Valve
Free flow (A1 to A2 or B1 to B2) is
permitted, but not both simultaneously
Ex: pressure from A1 to A2 exerts a force
on the spool, allowing flow from B2 to B1.
 Pilot-Operated Check Valves
Mechanically Piloted
When depressed by an external force, the pin
displaces the poppet
Commonly used as means for creating a
sequence of operating hydraulic actuators
 Flow Control Valves M.G.Rabie

Fluid flow is controlled by using throttling elements

Sharp-edged restrictors are viscosity independent
Approximately constant Cd = 0.611
Other shapes orifices have variable Cd
Temperature, viscosity, pressure.
 Flow Control Valves M.G.Rabie

Throttle Valves
Restricts flow in both directions

Consistofanadjustmentsleeve(1)
andaninnerhousing(2).Thefluid
flowsthroughtheradialdrillings(3)to
thethrottlingarea(4),whichis
definedbytheinnerhousing(2)and
theadjustmentsleeve(1).Thevalve
restrictionareaiscontrolledby
turningtheadjustmentsleeve(1).

BoschRexrothAG
 Flow Control Valves M.G.Rabie

Throttle-Check Valves
Restricts flow in one direction (free flow in the
opposite direction)

Thefluidpassesthroughtheradial
drillingsandthethrottlingarea(4).
Thethrottlingisachievedinone
direction.Inthereversedirection,the
pressureactsonthecheckvalve
poppet(5).Whenthepressure
differenceexceedsthecracking
pressure,thepoppetopens,allowing
reverseflow.

BoschRexrothAG
 Flow Control Valves M.G.Rabie

Sharp-Edged Throttle Valves

Independent of viscosity
Comprisedofahousing(1),anadjustingelement(2),andanorifice(3).Thefluidflow
(fromAtoB)isthrottledatanorificewindow.Thethrottleopeningisadjustedbyrotating
thecore(5),thelowerendofwhichisalipofhelicalshape.Thepreferreddirectionof
flowisfromAtoB.Thearea(3)oftheorificeiscontrolledbypositioningthesleeve(6),
usingtheadjustmentscrew(4).Thethrottlingareaisindicatedbymeansofan
adjustmentscaleatthetopsurfaceofthehousing(1).Duringoperation,theorificewith
theadjustmentscrewissupportedonthevalvemountingface.Thevariationofthe
throttleareawiththecorerotationalanglemaybelinearornonlinear,dependingonthe
shapeoftheorificeonthesleeve(6).

BoschRexrothAG
 Flow Control Valves
Used in fixed displacement pump (constant-flow)
circuits to control actuator speed
A non-pressure-compensated flow control valve is
also known as a ____________ valve
Creates a constriction (similar to constricting the
DCV) to slow the actuator

Pressure-compensated flow control valve

Changes orifice (i.e. pressure drop across the valve)
as the load pressure changes
Pressure across the relief valve
Pressure-Compensated Flow Control Valve
Pressure-Compensated Flow Control Valve
Pressure-Compensated Flow Control Valve
Series Pressure-Compensated FCV
Also called two-way FCV
Sharp-edged throttle and pressure compensator
(downstream) in series
 Pressure-Compensated Flow Control Valve
Series Pressure-Compensated FCV
Comprisedofahousing(1),ahandknobwithscale
(2),andadownstreampressurecompensator(4).The
flow(fromportAtoB)passesthroughtheorifice
window(5)onthesidewallofthehollowspool(3).
Therotationoftheknob(2)adjuststhevertical
positionofthespool(3)andthusdeterminesthe
areaofthethrottle(5).
Thepressurecompensationisachievedbythe
downstreamcompensator,whichconsistsofaspool
(4)andanorifice(8)connectedinserieswiththe
mainorifice(5).Thedisplacementofthespool(4)
upwarddecreasesthethrottlingareaoforifice(8)
andviceversa.Thespoolissubjectedtothepressure
andspringforces.Theinputchamberisconnectedto
thelowersideofthespool(4)throughthedamping
orifice(7).
BoschRexrothAG
Pressure-Compensated Flow Control Valve

Series Pressure-Compensated FCV

Actuator speed control
Pressure-Compensated Flow Control Valve
Parallel Pressure-Compensated Flow Control
Valve: Three-Way FCVs
 Flow Control Valve
With Bypass
Sleeve moves to set total pressure drop
required to maintain set flow to primary circuit
Excess flow bypass to secondary circuit
 Flow Dividers
Divide the flow from a single pump to supply two circuits
that operate at different pressures
50/50 to 90/10, generally in 10% increments

(1) Flowentrance
(2) Spool
(3) Fluidentrancetospool
(4) Splitfluidpassages
(5) Orificeatpassageend
(6) Flowexit
(7) Endplate
(8) Endofspool
 Flow Dividers
Spool Type
 Flow Dividers
Spool Type
Thevalveconsistsmainlyofthehousing(1),acontrolspool(2),andthree
springs(3).Thefluidflowfromtheport(P)isdividedintotwoequalpartial
flows.Thespringscenterthespoolaswellasassistinbalancingtheoutlet
flowswhenthereisapressuredifferenceattheoutletports(AandB).

BoschRexrothAG
 Flow Dividers
Displacement Type

Applicationofadisplacementtype
Displacementtypeflowdivider flowdividerasapressureintensifier
 SupplementalInformation
(Valves)
FluidPowerwithApplications,byA.Esposito
FluidPowerDesignHandbookbyF.Yeaple
 Modular Valving
Valve functions can be consolidated,
performance enhanced, and leaks
eliminated through modular valving
Stacked
Dilled plates
Labyrinths
Valve blocks with cartridges
 Stacked Valves Yeaple

Mated ports (with o-ring or gasket) to eliminate

interconnecting piping
Usually common supply and common drain
Stacked Valves Yeaple
 Drilled Plates Yeaple

Conceals piping
Flat mounting avoids
strains from connections
Maintenance simple:
front is independent of
back
Organized / labeled
Teaching platforms
Cartridge-type valves
can be inserted into
plate itself
 Labyrinths Yeaple

Typically milled (steel) or cast (cast iron) and

sandwiched
3D printed hydraulic systems/parts?
 Valve Block Yeaple

Foundation for cartridge

valves

Pressure drops lower

Passages are shorter
Time response improved

Tip: keep valves parallel

where possible

Careful of over-tightening
(damage valve block)
 Cartridge Valves
Many types available:
Relief, counterbalance, sequence, reducer, reducer-
relief, check (pilot), needle, pressure-compensated,
shuttle...
 Cartridge Valves Yeaple

Ex: Solenoid spool

Cartridge Valves Esposito
 Hydraulic Fuse (1) Esposito

Thin metal disk acts as a fuse

one time relief valve
Hydraulic Fuse (2)
Spring-loaded valves which
close the hydraulic line if they
detect a sudden increase in
flow
Ex: burst downstream

Preserves hydraulic fluid for

other services
Many types of sensors
Velocity, quantity,
Quantity

Used where safety is high

concern (aircraft)

http://www.predatorsystemsinc.com/fuses.html