MEM 341: FLUID

POWER
TECHNOLOGY
Chapter 5: Control Valves
 Chapter 5: Control Valves

5.1 Directional control valve

5.2 Pressure control valve
5.3 Flow control valve

If pump is considered the heart

for a hydraulic system, then
control valves can be considered
the brains of the system
 Introduction
• 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.

• This is down by using the control valves to regulate the

fluid flow in the system in terms of direction, pressure,
and flow rate.

• The three basic types of control valves are:

• Directional control
• Pressure control
Controlling the
• Flow control
System
 Shut-off/two-way Valve

Check Valve

Shuttle Valve
Directional Control
Valve Three-way Valve
Determines the path
Four-way Valve
through which a fluid
travels in a system
Pressure Relief Valve
Control Valves

Pressure Safety Valve

Pressure Control Pressure Sequence Valve

Valve
Protects the system Pressure Counterbalance
against overpressure valve

Pressure Unloading valve

Pressure Reducing valve

Flow Valve
Flow Control
Valve Throttle Valve
Controls the flow
rate in the system
 5.1 Directional Control Valves (DCV)
• Directional control devices allow a system operator to
control the direction of fluid flow in the system such as:
❖ Starting and stopping of actuators
❖ Controlling of actuator movement direction

• Directional control devices can be grouped in five general

classifications:
1) Shut-off or two-way valves
2) Check valves
Directional
3) Shuttle valves Control Valve
4) Three-way valves
5) Four-way valves
• Any valve contains ports that are external openings through
which fluid can enter and leave via connecting pipelines.

• The number of ports on DCV is identified using the term way.

• Ex: a valve with four ports is a four-way valve.

1) SHUT-OFF or TWO-WAY VALVES
• The primary purpose of shut-off valves is to block fluid
flow through a hydraulic system line, for example globe
valves, and needle valve.

Shut-off
valve symbol
Needle Valve
Globe Valve
 2) CHECK VALVES
• The primary purpose of check valves is to allow free flow in one
direction while preventing reverse flow.

• Other functions include:

❖ Bypassing components during the return cycle of the system
❖ Providing flow resistance to maintain a minimum system pressure required
for pilot operations

• A standard check valve consists of a valve body containing a

one-way valve located between inlet and outlet ports
❖ The one-way valve allows fluid flow through the valve in only one direction
❖ Some designs contain a spring that seats the valve poppet or ball
❖ In other designs, the poppet is seated only by fluid flow
Check valve
symbol
3) SHUTTLE VALVES
• It permits a system to operate from either of two fluid
power sources.
• Consists a floating piston that can be shuttled to one side
or the other of the valve depending on which side the
piston has the greater pressure.

Symbol of
shuttle valve
 4) THREE-WAY VALVES
• Three-way directional control valves provide a means to
extend rams and single-acting cylinders.
• Three-way directional control valves are typically
manufactured as two-position valves
• The actuator is returned to its original position by an
external force:
• System load, or
• Spring built into the actuator

Three-way Three-way
Valve symbol Valve
Operation for a Three-way Valve

• During extension, the three-way valve connects the

actuator inlet line to a system supply line, allowing fluid to
enter and extend the unit

• During retraction, the valve blocks the supply line and

connects the actuator line to a system return line, allowing
external force to return the actuator to its original
position while directing displaced fluid to the reservoir
5) FOUR-WAY VALVES
• Four-way directional control valves provide a means
to power actuators in either direction.
❖ Valve has four external ports for connection to
system supply line, reservoir, and inlet and outlet of
the actuator
❖ Internal structure of the valve allows the ports to be
alternately connected when a change in actuator
direction is necessary
❖ Four-way directional control valves are typically
manufactured as two- or three-position valves
❖ This provides several operating options when
designing circuits

Four-way
Valve symbol
Operation for a Four-way Valve

• In two-position valves, the first position operates the

actuator in one direction, while the second position
reverses the direction

2/4 DCV

• In three-position valves, a center position is added that

provides additional circuit operating characteristics
Operation for a Four-way Valve

• In three-position valves, a center position is added that

provides additional circuit operating characteristics

3/4 DCV
• A number of center position configurations are available:

Center Position
Configuration

• The center position affects directional

control characteristics and overall
system efficiency

• Each style provides distinct operating

characteristics that allow hydraulic
system designers to obtain maximum
performance from a system
Application of Four-
way Valve
Activation Methods for 3-way of 4-Way Valves

• A number of activation methods are used to shift the

positions of directional control valves
i. Manual operation (i.e. Handwheels, Levers, Push
buttons, Foot pedals)
• These devices require constant operator presence
and are typically found in less-complex systems
ii. Mechanical operation (i.e Rollers, Cams, Levers,
Rams)
• Mechanical operation is often used when the
opening and closing of the valve must occur at a
specific position in actuator travel

Mechanical
Activation Method
iii. Pilot operation (Fluid or Air Pressure)

• Pilot operation uses system pressure to activate the valve,

rather than physical labor

• This method is effective when:

❖Larger forces are need to shift the valve
❖Remote operation is required because of safety or
tight physical factors

Pilot Activation
Method
Symbols for Directional Control Valves

Symbol for DCV

• DCV’s are represented using square boxes.

• Each square box represents the position

❖ i.e. Number of boxes in figure specifies the number of
valve operating positions.
• Each square box requires ports.
❖ Ports are passages/holes drilled through a control valve
to which fluid passes through.

• Must have at least 2 ports

• Ports are represented using inverted T’s

• Arrows inside a square indicates the direction of fluid
flow.

• Normally control valves with more than 1 position, includes

springs at either one or both ends of the control valves.

• The purpose of springs is to return the control valve to its

original position.
Example: Direction control valves (DCV)
5.2 Pressure Control Valves
Pressure control valves may be grouped into one of five types:
1) System maximum pressure control
i. Pressure Relief Valve
2) Actuator sequence control
ii. Pressure Sequence Valve
3) Restrained movement control
iii. Pressure Counterbalance Valve
Functions of PCV
4) Pump unloading control
iv. Pressure Unloading Valve
5) Reduced pressure control
v. Pressure Reducing Valve
• Pressure control valves can be either normally open or normally
closed valves

Normally open or
closed
i) Pressure Relief Valve

• Pressure relief valves are normally closed valves.

• They open when system pressure approaches the set

maximum operating pressure.

• Once activated, the pressure relief valve will allow excess

fluid to return to the reservoir.

Pressure Relief
Valve
ii) Pressure Sequence Valve

• Sequence valves allow the automatic sequencing of two or

more actuators in a hydraulic circuit.

• 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

Hydraulic Circuit
containing Pressure
Relief and Sequence
Valves
iii) Pressure Counterbalance Valve

• Pressure Counterbalance valve is used in circuits to prevent

unexpected actuator movement.

• For example, Counterbalance valves prevent unexpected lowering

of the boom.

• Counterbalance valve is normally a closed valve.

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

valve.

• Counterbalance valves allow the downward movement of loads

supported by a cylinder only when the system pump is operating.

Hydraulic Circuit
containing Pressure
Counterbalance valve
iv) Pressure Unloading Valve

• Pressure unloading valve hold a desired operating pressure while

the pump operates at near-zero pressure

• This reduces energy consumption and maintenance costs.

• The use of an accumulator is required to maintain desired system

pressure while dumping unneeded pump output to the reservoir at
very low pressure.

Hydraulic Circuit
containing Pressure
Unloading Valve
v) Pressure Reducing Valve

• Pressure reducing valve allows a portion of a system to operate

at a pressure below the maximum pressure setting of the system
relief valve.

• Pressure-reducing valves are normally open valves with an internal

pilot and external drain.

Hydraulic Circuit
containing Pressure
Reducing Valve
 Pressure Control Valves (PCV)
Name Symbol Function

• used to protect the hydraulic system

Pressure Relief Valve from pressure overload, also called a
safety valve

• used to release the flow to a futher

Pressure Sequence Valve hydraulic system when a certain pressure
is reached in the main system

• used to block the flow to a futher

hydraulic system when a certain pressure
is reached in the main system

• it is used to permit a pump to build

pressure to an adjustable pressure
Pressure Cut-off Valve setting and then allow it to discharge oil
to the tank at essentially zero pressure.
• it is used to maintain control of a vertical
hydraulic cylinder to prevent it from
decending due to the weight of its
external load.

• used to keep a certain part of the

Pressure Reducing Valve
hydraulic system at a lower pressure.
 5.3 Flow Control Valves
• Used to regulate the speed of hydraulic cylinders and
motors by controlling the flow rate.

• Can be divided into throttle valve and flow valves.

• Design of flow control valve may be simple as a fixed

orifice meter or an adjustable needle valve.

• Can be divided into throttle valve and flow valves.

Adjustable Needle
Fixed Orifice Meter valve
• Flow control valves may be non-compensated or compensated
❖ The flow rate through non-compensated valves varies as the
load or fluid viscosity changes
❖ Compensated valves automatically adjust for fluid pressure
variations to produce a consistent flow rate under varying
load and temperature conditions

• Non-pressure-compensated: used where system pressure is

relatively constant and motoring speeds are not too critical.
➢ Work on the principle that the flow through an
orifice will be constant if the pressure drop remains
constant.

• Pressure-compensated : Used when load on an actuator changes

significantly. Thus flow rate through a non-pressure-
compensated valve will change for the same flow rate setting.

• Pressure compensator maintains a constant pressure difference

across the metering orifice of a flow control valve by:
❖ Sensing pressure on the inlet and outlet sides of the orifice.
• A temperature compensator is necessary in flow control devices
if an accurate, consistent flow rate through a valve is needed
❖ This is due to the fluid viscosity changes that occur as fluid
temperature changes
❖ Temperature compensation is typically accomplished in flow
control devices by heat-sensitive metal rod that operates a
needle like control device in the metering orifice of the valve.

Hydraulic Circuit
with Pressure
Compensator Flow
Control Valve
 Flow Control Valves Classification
Non-pressure compensated Pressure compensated

System pressure is relatively If monitoring speed is critical to the

constant and monitoring speed are system than system pressure will also
not too critical. change significantly

Flow rate will change as a result of

Flow rate remains constant if the
change in system pressure. Used when
pressure drop remains constant
load on an actuator changes significantly.

The presence of a hydrostat detects the

change in system pressure.
TEST 1 MEM341

DATE: 8/8/2016 (Monday)

TIME: 9.00 – 10.00 AM
VENUE: DEWAN PERAK & DEWAN EMAS
CHAPTER COVER: CHP 1 - 5