2.

Hydraulic Valves, Actuators and

Accessories

24 Marks
 Co related to chapter

• 602.2
Describe working principle of various
components used in hydraulic & pneumatic
systems.
• 602.3
Choose valves, actuators and accessories
required for simple hydraulic and pneumatic
circuits.
 Pressure-control valves

• Function
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.
 Types of pressure control valves
• Pressure-relief valve.
• Pressure-reducing valve.
• Unloading valve
• Counterbalance valve.
• Pressure-sequence valve.
 Pressure Relief valves
• The pressure relief valves are used to protect
the hydraulic components from excessive
pressure.
• It is normally a closed type and it opens when
the pressure exceeds a specified maximum
value by diverting pump flow back to the tank.
• Schematic of direct Direct type of relief valve
pressure relief
valve is shown in
figure 5.6.1.
• 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 Direct type of relief valve
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 Direct type of relief valve
reseats as the
pressure drops
below the pre-set
value.
• A drain is also
provided in the
control chamber.
• It sends the fluid
collected due to
small leakage to
the tank and
thereby prevents
the failure of the
valve.
Three-dimensional view of simple pressure-relief valve.
Compound relief valve or pilot
operated relief valve
Compound relief valve or pilot
operated relief valve
symbol

VIDEO 1
 Pressure Reducing Valve
• Sometimes a part of the system
may need a lower pressure. This
can be made possible by using
pressure reducing valve as shown
in Figure .
• These valves are used to limit the
outlet pressure.
• Generally, they are used for the
operation of branch circuits
where the pressure may vary
from the main hydraulic pressure
lines.
• These are open type valve and
have a spring chamber with an
adjustable spring, a movable
spool as shown in figure.
• 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.
• When the outlet (downstream)
pressure increases to the valve
setting, the spool moves to the up
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.
Three-dimensional view of a pressure-
reducing valve and symbol

VIDEO 2
 Direction control valve
• Definition:
• A valve 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.
• Function:
The function of a DCV is to control the
direction of fluid flow in any hydraulic system.
 Direction control valve
• 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.
VALVE BODY
OUTLET-B
SPOOL

INLET-A
 Direction control valve
• Sliding spool type:
• In this type, the spool
is slides to change
the direction of fluid.
A

B
 Check Valve
• The simplest DCV is a
check valve.
• A check valve allows flow
in one direction, but
blocks the flow in the
opposite direction.
• It is a two-way valve
because it contains two
ports.
• Figure 1.1 shows the
graphical symbol of a
check valve along with its
no-flow and free-flow
directions.
 Ball type check valve
• In Fig. 1.2, a light spring holds the ball against the valve seat.
Flow coming into the inlet pushes the ball off the seat against
the light force of the spring and continues to the outlet.
• A very low pressure is required to hold the valve open in this
direction.
• If the flow tries to enter from the opposite direction, the
pressure pushes the ball against the seat and the flow cannot
pass through.
• VIDEO
 Poppet check valve
• Figure 1.3 provides two schematic drawings showing the
operation of a poppet check valve. A poppet is a specially
shaped plug element held on a valve seat by a light spring.
Fluid flows through the valve in the space between the seat
and poppet. In the free flow direction, the fluid pressure
overcomes the spring force. If the flow is attempted in the
opposite direction, the fluid pressure pushes the poppet in
the closed position. Therefore, no flow is permitted
 Pilot-Operated check Valve
• A pilot-operated valve
along with its symbol
is shown in Fig. 1.4.
This type of check
valve always
• permits free flow in
one direction but
permits flow in the
normally blocked
opposite direction
only if the pilot
pressure is applied at
the pilot pressure
point of the valve.
• The check valve
poppet has the pilot
piston attached to the
threaded poppet stem
by a nut.
 Pilot-Operated check Valve
• The light spring holds
the poppet seated in a
no-flow condition by
pushing against the
pilot piston.
• The purpose of the
separate drain port is
to prevent oil from
creating a pressure
build-up at the bottom
of the piston.
• The dashed line in the
graphical symbol
represents the pilot
pressure line
connected to the pilot
pressure port of the
valve. Pilot check
valves are used for
locking hydraulic
cylinders in position.
 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 1.5 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 .
 2/2 DIRECTION CONTROL VALVE:

This valve has two ports and two positions of spool. The two ports are inlet
port-A and outlet port-B.

Sliding spool type 2/2 DCV:

The figure shows a sliding spool type

spring return type Normally Closed
2/2DCV. A
In normal position of the spool, the
ports are closed; fluid cannot flow from B
port-A to port-B
When the palm button is pressed,
spool moves to open the passage from
port-A to port-B.

VIDEO
 Rotary spool type 2/2 DCV:

VALVE BODY
OUTLET-B
SPOOL

INLET-A

The figure shows a rotary spool type 2/2DCV.

In first position of the spool, the ports are closed; fluid cannot flow from
port-A to port-B
When the spool is rotated through 90O, it opens the passage from port-A to
port-B,
VIDEO
 3/2 DIRECTION CONTROL VALVE:

This valve is used to operate single acting cylinders. It has three ports
namely, Pump port or inlet port “P”, Cylinder port “A” and Tank port or exhaust
port “T”.
3/2 sliding spool type valve:
The figure shows spring return type sliding spool valve. It has a spring-
loaded spool inside the valve body. In figure, it is palm-operated type of
valve.
A
In spool position as shown in figure,
there is connection from port-A to port-T.
Inlet port port-P is closed.
In spool position as shown in P T
figure, there is connection from port-P to
A
port-A. The tank port or exhaust port,
that is, port-T is closed.

VIDEO P T
 3/2 rotary spool valve:

The figure shows a 3/2 rotary spool valve. It has rotary spool inside the
valve body. The spool is rotated through 120O to operate the valve.

A
valve body
In spool position as shown in figure, there is
connection from P to A. Fluid flows from pump to
single acting cylinder. Hence the cylinder
extends. The tank port or exhaust port, that is,
port-T is closed. P
T
When the spool is turned to 120O, that is, as spool
shown in shown in figure, there is connection A
from port-A to port-T. Fluid flows from single
acting cylinder to tank. Hence the cylinder
retracts. The inlet port port-P is closed.

VIDEO P T
 4/2 DIRECTION CONTROL VALVE:
This valve is used to operate double acting cylinders.
It has four ports namely, Pump port or inlet port “P”, Cylinder port “A”,
Cylinder port “B” and Tank port or exhaust port “T”.

4/2 sliding spool valve:

In spool position as shown in A P B T

figure-A, there is connection from
P to A and B to T. Fluid flows form
pump to port-A and form port-B to
tank.
When the palm button is pressed,
the spool position is as shown in
figure-B, there is connection from A P B T

P to B and A to T. Fluid flows form

pump to port-B and form port-A to
tank.

VIDEO
 4/2 rotary spool valve:

The figure shows a 4/2 rotary spool valve. It has rotary spool inside the
valve body. The spool is rotated through 90O to operate the valve.
T T
valve body

A B A B

spool
P P

In spool position as shown in figure-A, there is connection from P to A and

B to T. Fluid flows form pump to port-A and form port-B to tank. Hence the
double acting cylinder extends.
When the spool is turned to 90O, that is, as shown in shown in figure-B,
there is connection from P to B and A to T. Fluid flows form pump to port-B and
form port-A to tank. Hence the double acting cylinder retracts.
VIDEO
 5/2 DIRECTION CONTROL VALVE:
This valve is used to operate double acting cylinders.
It has 5 ports namely, Pump port or inlet port “P”, Cylinder port “A”, Cylinder port
“B” Tank port or exhaust port “T1” and Tank port or exhaust port “T2”.
5/2 sliding spool valve:
In spool position as shown in figure,
A B
there is connection from P to A and B to
T2. Fluid flows form pump to port-A and
form port-B to tank. Hence the double
acting cylinder extends
T1 P T2
When the palm button is pressed, the
spool position is as shown in figure-B,
there is connection from P to B and A to A B
T1. Fluid flows form pump to port-B and
form port-A to tank. Hence the double
acting cylinder retracts.
T1 P T2

VIDEO
 5/2 rotary spool valve:

The figure shows a 5/2 rotary spool valve. It has rotary spool inside the
valve body. The spool is rotated through 72O to operate the valve.
T1
T1 T2 T2
valve body
valve body

B B
A
A
spool spool
Figure-A Figure-B
P P
In spool position as shown in figure-A, there is connection from P to A
and B to T2. Fluid flows form pump to port-A and form port-B to tank. Hence
the double acting cylinder extends.
When the spool is turned to 72O, that is, as shown in shown in figure-B,
there is connection from P to B and A to T1. Fluid flows form pump to port-B
and form port-A to tank. Hence the double acting cylinder retracts.

VIDEO
METHODS OF ACTUATION
METHODS OF ACTUATION
Types of different center positions.
 Flow control valve
• Flow-control valves, as the name suggests,
control the rate of flow of a fluid through a
hydraulic circuit.
Applications :
• 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.
 Functions of Flow-Control Valves
• Flow-control valves have several functions, some
of which are listed below:
1. Regulate the speed of linear and rotary actuators:
They control the speed of piston that is dependent
on the flow rate and area of the piston:
2. Regulate the power available to the sub-circuits by
controlling the flow to them:
3. Proportionally divide or regulate the pump flow to
various branches of the circuit: It transfers the
power developed by the main pump to different
sectors of the circuit to manage multiple tasks, if
necessary.
 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.
• A non-compensated flow control passes more
or less fluid as pressure increases and
decreases.
• This is because more fluid can pass through a
certain size orifice when pressure drop
(pressure difference) across the orifice
increases.
 Non-Pressure-Compensated Valves
• 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 work
load. 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.
Non-pressure-compensated needle-
type flow-control valve
 Non-pressure-compensated needle-
type flow-control valve
• Schematic diagram of non-pressure-compensated
needle-type flow-control valve is shown in Fig. 1.3.
• It is the simplest type of flow-control valve.
• It consists of a screw (and needle) inside a tube-like
structure.
• It has an adjustable orifice that can be used to reduce
the flow in a circuit.
• The size of the orifice is adjusted by turning the
adjustment screw that raises or lowers the needle.
• For a given opening position, a needle valve behaves as
an orifice.
 Non-pressure-compensated needle-
type flow-control valve
• Sometimes needle valves
come with an integrated
check valve for
controlling the flow in
one direction only.
• The check valve permits
easy flow in the opposite
direction without any
restrictions. As shown in
Fig. 1.4, only the flow
from A to B is controlled
using the needle. In the
other direction (B to A),
the check valve permits
unrestricted fluid flow.
 Pressure-Compensated Valves
• Pressure-compensated flow-control valves overcome
the difficulty caused by non-pressure-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.
Pressure-Compensated Valves
 Pressure-Compensated Valves
• A pressure-compensated
flow-control valve consists
of a main spool and a
compensator spool.
• The adjustment knob
co trols the ai spool’s
position, which controls the
orifice size at the outlet.
• The upstream pressure is
delivered to the valve by
the pilot line A.
• Similarly, the downstream
pressure is ported to the
right side of the
compensator spool through
the pilot line B.
• We want to keep
pressure drop (pressure
difference on both side of
knife edge orifice) is 100
to 150 psi.
• The compensator spool is
held open by a 100- to
150-psi compression
spring that sets pressure
drop across the knife-
edge orifice.
• Flow from the inlet goes
through the
compensating orifice,
past the compensator
spool, and out through
the knife-edge orifice.
• A drilled passage ports
Inlet fluid to the left end
of the compensator
spool, which forces the
spool to the right when
pressure tries to go above
100 to 150 psi.
• After pressure reaches or
goes above 100 to 150
psi, the compensator
spool moves to the right
and restricts flow to the
knife-edge orifice flow
control.
• Pressure at the outlet is
ported to the
compression-spring
chamber and increases
the spring force.
• The compensator spool
assures that pressure
drop across the knife-
edge orifice flow control
stays at a constant 100 to
150 psi.
• With a constant pressure
drop, flow stays the same
regardless of inlet or
outlet fluctuations.
 Actuators
• Hydraulic actuators are devices used to convert
pressure energy of the fluid into mechanical
energy.

• Depending on the type of actuation, hydraulic

actuators are classified as follows:
• 1. Linear actuator: For linear actuation (hydraulic
cylinders).
• 2. Rotary actuator: For rotary actuation (hydraulic
motor).
• 3. Semi-rotary actuator: For limited angle of
actuation (semi-rotary actuator).
 1.2 Types of Hydraulic Cylinders
• Hydraulic cylinders are of the following types:
• Single-acting cylinders.
• Double-acting cylinders.
• Telescopic cylinders.
• Tandem cylinders.
 1.2.1 Single-Acting Cylinders

• A single-acting cylinder is simplest in design and is shown

schematically in Fig.1.1.
• It consists of a piston inside a cylindrical housing called barrel.
• On one end of the piston there is a rod, which can reciprocate.
• At the opposite end, there is a port for the entrance and exit of oil.
 1.2.1 Single-Acting Cylinders

• Single-acting cylinders produce force in one direction by hydraulic

pressure acting on the piston.
• (Single-acting cylinders can exert a force in the extending direction
only.)
• The return of the piston is not done hydraulically. In single-acting
cylinders, retraction is done either by gravity or by a spring.
 1.2.2 Double-Acting Cylinder

• There are two types of double-acting

cylinders:
• Double-acting cylinder with a piston rod on
one side.
• Double-acting cylinder with a piston rod on
both sides.
 Double-Acting Cylinder with a Piston
Rod on One Side

• Figure 1.4 shows the operation of a double-acting cylinder

with a piston rod on one side. To extend the cylinder, the
pump flow is sent to the blank-end port as in Fig. 1.4(a). The
fluid from the rod-end port returns to the reservoir. To retract
the cylinder, the pump flow is sent to the rod-end port and
the fluid from the blank-end port returns to the tank as in
Fig.1.4(b).
Double-Acting Cylinder with a Piston Rod on Both Sides

A double-acting cylinder with a piston rod on both sides (Fig.1.5)is

a cylinder with a rod extending from both ends. This cylinder can
be used in an application where work can be done by both ends of
the cylinder, thereby making the cylinder more productive. Double-
rod cylinders can withstand higher side loads because they have an
extra bearing, one on each rod, to withstand the loading.
 1.2.3Telescopic Cylinder
• A telescopic cylinder (shown in
Fig. 1.6) is used when a long
stroke length and a short
retracted length are required.
• The telescopic cylinder extends
in stages, each stage consisting
of a sleeve that fits inside the
previous stage.
• One application for this type of
cylinder is raising a dump truck
bed.
• Telescopic cylinders are
available in both single-acting
and double-acting models.
• They are more expensive than
standard cylinders due to their
more complex construction.
 Telescopic Cylinder
• They generally consist of a nest of tubes and
operate on the displacement principle.
• The tubes are supported by bearing rings,
the innermost (rear) set of which have
grooves or channels to allow fluid flow.
• The front bearing assembly on each section
includes seals and wiper rings.
• Stop rings limit the movement of each
section, thus preventing separation. When
the cylinder extends, all the sections move
together until the outer section is
prevented from further extension by its stop
ring.
• The remaining sections continue out-
stroking until the second outermost section
reaches the limit of its stroke; this process
continues until all sections are extended,
the innermost one being the last of all.
 Tandem cylinder

• A tandem cylinder, shown in Fig. 1.7, is used in applications

where a large amount of force is required from a small-
diameter cylinder.
• Pressure is applied to both pistons, resulting in increased force
because of the larger area.
• The drawback is that these cylinders must be longer than a
standard cylinder to achieve an equal speed because flow
must go to both pistons.
Rotary actuators-Hydraulic motors
• Hydraulic motors are rotary actuators.
However, the name rotary actuator is reserved
for a particular type of unit that is limited in
rotation to less than 360.
• A hydraulic motor is a device which converts
fluid power into rotary power or converts fluid
pressure into torque
Pumps and motors
Classification of Hydraulic Motors

• 1. Gear motors.
• 2. Vane motors.
• 3. Piston motors:
A) Axial piston-type motors.
B) Radial piston-type motors.
Gear Motors:
 Vane motors-unbalanced type
Figure 1.2 shows an unbalanced
vane motor consisting of a
circular chamber in which there
is an eccentric rotor carrying
several spring or pressure-
loaded vanes. Because the fluid
flowing through the inlet port
finds more area of vanes
exposed in the upper half of the
motor, it exerts more force on
the upper vanes, and the rotor
turns counterclockwise. Close
tolerances are maintained
between the vanes and ring to The displacement of a vane hydraulic motor is a
provide high efficiencies. function of eccentricity. The radial load on the
shaft bearing of an unbalanced vane motor is also
large because all its inlet pressure is on one side of
the rotor.
 Balanced type vane motor
The radial bearing load problem is
eliminated in this design by using a
double-lobed ring with diametrically
opposite ports. Side force on one side
of bearing is canceled by an equal and
opposite force from the diametrically
opposite pressure port. The like ports
are generally connected internally so
that only one inlet and one outlet port
are brought outside. The balanced
vane-type motor is reliable open-loop
control motor but has more internal
leakage than piston-type and
therefore generally not used as a
servo motor.
 Swash plate piston motor

In axial piston motors, the piston reciprocates parallel to the axis of the cylinder block.
These motors are available with both fixed-and variable-displacement feature types.
They generate torque by pressure acting on the ends of pistons reciprocating inside a
cylinder block. Figure 1.4 illustrates the inline design in which the motor, drive shaft and
cylinder block are centered on the same axis. Pressure acting on the ends of the piston
generates a force against an angled swash plate. This causes the cylinder block to rotate
with a torque that is proportional to the area of the pistons. The torque is also a
function of the swash-plate angle. The inline piston motor is designed either as a fixed-
or a variable-displacement unit. The swash plate determines the volumetric
displacement
 Bent axis motor
A bent-axis piston motor
is shown in Fig.1.6. This
type of motor develops
torque due to pressure
acting on the
reciprocating piston. In
this motor, the cylinder
block and drive shaft
mount at an angel to
each other so that the
force is exerted on the
drive shaft flange.
Pipes and Pipe Fittings
 Necessity of pipes and hoses
• In hydraulic system the hydraulic energy is carried by means
of closed conduits/pipes.
• These pipes are designed to carry the high pressure fluid and
to provide flexibility and strength.
• Fluid power lines classified as:
a) Pipe (Rigid)
b) Tubes ( Semi Rigid)
c) Hoses (Flexible)
 Characteristic features of Pipes
• They are rigid and suitable for very high pressure application.
• They are not generally bent.
• Used for permanent application.
• These have maximum strength out off all three pipes.
• These are specified by the nominal bore size and wall
thickness i.e. for a given ID it can have various OD.
• Pipes are generally made of metals.
 Characteristic features of Tubes
• They are made of comparatively flexible materials.
• They can be bent to any shape and are easy to work.
• It can be used over and over again.
• Tubes are specified based on their outer diameter(OD)
• Tubes are suitable for light weight applications.
 Characteristic features of Hoses
• Hoses have same strength as pipe.
• Relative movement is possible between the points it is
connected.
• Easy to install and dismantle.
Properties of fluid Power Conduits
• Mechanical strength: It should have sufficient strength to
withstand the subjected pressure.
• Supporting strength: To support the components and fitting
mounted on the piping
• Terminal points: To facilitate dismantling and assembling
during servicing /repair
• Damping capability: Should dampen out shock waves which
may develop in the system accidentally.
• Smoothness of surfaces: The inner surface of the pipe should
be sufficiently smooth to reduce friction losses.
Selection of Pipes,Tubes and Hoses
It is based on
• Required strength in the system
• Pressure needed in the system
• Requirement of flexibility of the actuator
• Availability of materials for maintenance.
• Ease of replacement.
 Pipe materials
• Steel : Due to Low cost , easy to bend, easy to connect.
For high pressure application
• Copper: Due to high resistance to corrosion.
For low pressure application.
• Aluminium : Light in weight, good resistance to corrosion.
For air craft and missile hydraulic system
• Stainless steel: Corrosion free, Good strength.
Due to high cost suitable for particular
application.
 Selection of Pipe dimension
Three imp. Dimensions of pipes are considered:
• Outside diameter (OD)
• Inside diameter (ID)
• Wall thickness
Pipes are specified by their nominal ID and wall thickness.
Selection of ID:
• Based on flow rate of fluid
• Permissible frictional losses.
 Schedule of Pipes
Pipes are classified based on their wall thickness
• Standard pipes
• Extra strong ( Extra heavy)pipes
• Double extra strong ( Double extra heavy ) pipes
The wall thickness is expressed as a schedule number and is
specified by ANSI(American National standard Institute)
Standard: Schedule 40
Extra strong : Schedule 80
Double extra strong : Slightly thicker than Schedule 160
For given ID greater the wall thickness greater will be the
bursting pressure
 Tubes and Tubings
They are semi Rigid.
Tubing size :
• Tubes are designed by its actual OD e.g. 5/8 inch tube means
having and OD of 5/8 inch.
• Tubes are given numbers in increments of 1/16 inch e.g. No. 6
tube means if will have an OD of 6/16 inch.
• Standard pipes and tubes are available between sizes from 1/16
to 2 inch nominal size.
Hoses
 Construction of Hoses
• It is divided into three layers:
a) Inner tube b) reinforcement c) outer covering
a) Inner tube :This is the passage through which the oil would be
flowing.It is made of a suitable hoses material.Selection of ID
of this tube is done as in case of pipes.
b) Reinforcement:
• The inner tube is covered with reinforcement material to
provide sufficient strength to it.
• It is made up of fiber or steel wire braiding.
• Depending on pressure ,two or three layers may be given.
c) Outer covering :
• To avoid reinforcement from getting damaged by the impact or
sharp objects outer protective cover is given.
• It also covers reinforcement form abrasion,corrosion nad
other damages.