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Unit 3
Fluid Power Control
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Introduction-
Most important consideration in any fluid power system is
Control.
If control components are not properly selected the entire
system will not function as required.
The fluid power is controlled primarily through use of control
devices called Valves.
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Control Valves-In fluid power, controlling elements are called valves.
There are three types of valves:A. Directional control valves (DCVs) : They determine the path
through which a fluid traverses a given circuit.
Eg- Check valve, 2-way, 3-way, 4-way DCV etc
B. Pressure control valves (PCVs) : They protect the system
against over pressure, which may occur due to a sudden surge
as valves open or close or due to an increase in fluid demand.
Eg- Pressure Relief, Pressure reducing, Sequencing, Unloading
etc.
C. Flow control valves (FCVs) : To control flow rate in various
lines of circuit. The control of actuator speed depends on flow
rate.
Eg- Globe valve, etc
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A.DCVs:Receives an external signal (mechanical, fluid pilot signal,
electrical or electronics) to release, stop or redirect the fluid
that flows through it.
Function to control the direction of fluid flow in any
hydraulic system. A DCV does this by changing the position of
internal movable parts.
Classification of DCVs:Based on fluid path,
1. Check valves.
2. Shuttle valves.
3. Two-way valves.
4. Three-way valves.
5. Four-way valves.
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1. Check valves:Allows flow in one direction, but blocks the flow in the opposite
direction.
Two-way valve because it contains two ports.
Ball-type check valve.
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2.Shuttle valvesAllows two alternate flow sources to be connected in a one-branch circuit.
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a. Forward Stroke b. Return Stroke
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3. 2/2-Way DCV
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A pair of two-way valves is used to fill and drain a vessel.
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4. 3/2-Way DCV
P
A
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5. 4/2 DCV.
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4/3 directional control valve
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PRESSURE-CONTROL VALVES
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B.PRESSURE-CONTROL VALVES
PCV 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.
Functions:
1.Limiting maximum system pressure at a safe level.
2.Regulating/reducing pressure in certain portions of the
circuit.
3.Unloading system pressure.
4.Assisting sequential operation of actuators in a circuit with
pressure control.
5.Any other pressure-related function by virtue of pressure
control.
6.Reducing or stepping down pressure levels from the main
circuit to a lower pressure in a sub-circuit.
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Valves used for pressure control:
1.Pressure-relief valve.
2.Pressure-reducing valve.
3.Unloading valve
4.Counterbalance valve.
5.Pressure-sequence valve.
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1.Pressure-Relief Valves (PRV)
Functions:
1. PRV limit the maximum pressure in a hydraulic circuit by
providing an alternate path for fluid flow when the pressure
reaches a preset level.
2. All fixed-volume pump circuits require a relief valve to protect
the system from excess pressure.
Types-
1. Direct Acting Relief Valve.
2. Pilot Operated Relief valve.
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1. Direct Acting Relief Valve-
Function is to limit the pressure to a specified maximum value by
diverting pump flow back to the tank.
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Construction & Working-
It consists of a valve body, poppet, spring and adjusting screw.
Poppet held on valve seat by spring compression, which is
adjusted by screw.
When pressure at inlet is insufficient to overcome the force of the
spring, the valve remainder on reaching closed. The pre-set
pressures reached the oil pressure over came the spring forces
and force off the poppet from its seat and by-passes sits on its
seal to tank. And poppet will remain lifted till pressure is above
pre-set pressure. As pressure reduces poppet again block
bypassing of oil to tank.
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Advantage of direct-acting relief valves over pilot-operated relief valves
is that they respond very rapidly to pressure buildup. Because there is
only one moving part in a direct-acting relief valve, it can open rapidly,
thus minimizing pressure spikes.
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1.2.Compound Pressure Relief Valve(Pilot-Operated Pressure Relief
Valve):
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Pilot-Operated Pressure Relief Valve (cont…)
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Construction & Working-
In case of direct acting relief valve the pressurized fluid is stop by spring
loaded poppet against by-passing to the reservoir. While in case of pilot
operated relief valve a balanced piston or spool block the passage of
pressurized fluid against bypassing to reservoir. Excess pressure cause
unbalances of the piston, because of which it slides to one side allowing
pressurized fluid to by-pass to the reservoir. One side chamber of piston is
connected to pressure port of direct acting relief valve.
And other side of the chamber to the pressure line of pump. Both the
chambers are connected by small orifice. Because of which pressure on both
the sides are same, and there is no continuous flow of fluid in either side of
balance piston across orifice. As pressure increase, the poppets of direct acting
relief valve get lifted and pressurized fluid bypasses to reservoir.
This causes a flow of fluid across the orifice, when fluid flow through small
orifice, their pressure drops due to throttling. Hence on this side of chamber
there is less pressure than pump side. Hence this difference in pressure cause
an unbalance force on piston and it slides to low-pressure side. This side
shifting of piston open path to pressurized fluid of pump to bypass to
reservoir.
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Remote Control Pilot Operated relief Valve:A direct acting relief valve connected to pilot operated relief valve at vent port.
Adjusting main valve is very risky, as even if by mistake or oversight operator
increase pressure beyond safe limit of system, press will get damage. Hence
another addition relief valve should be fitted on control panel.
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Solenoid Operated Pilot Operated Relief Valve:
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2.Pressure-reducing valveUsed to maintain reduced pressures in specified locations of hydraulic
systems.
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The disadvantage of this method is that the pressure drop across the
reducing valve represents the lost energy that is being converted into heat.
If the pressure setting of the reducing valve is set very low relative to the
pressure in the rest of the system, the pressure drop is very high, resulting in
excessive heating of the fluid.
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3. Unloading valve:
Used to dump excess fluid to the tank at little or no pressure.
A common application is in high flow-low pressure pump circuits where two
pumps move an actuator at a high speed and low pressure
The circuit then shifts to a single pump providing a high pressure to perform
work
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When punching operation begins, the increased pressure opens the
unloading valve to unload the low-pressure pump.
The check valve protects the low-pressure pump from high pressure, which
occurs during punching operation
Application of Unloading valve in a punching press (high–low circuit).
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4. Counterbalance valveUsed to maintain a back pressure on a vertical cylinder to prevent it from
falling due to gravity.
They are used to prevent a load from accelerating uncontrollably.
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Counterbalance valve (cont..)
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Application of a Counterbalance Valve
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5. Pressure Sequence Valve
Used to force two actuators to operate in sequence
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Flow-control valves:Control the rate of flow of a fluid through a hydraulic circuit.
Their function is to provide velocity control of linear
actuators, or speed control of rotary actuators.
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.
FCV also allow one fixed displacement pump to supply two or
more branch circuits fluid at different flow rates on a priority
basis.
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Flow-control valves can be classified as follows: 1.Non-pressure compensated. a. Gate FCV
b. Globe FCV
c. Needle FCV
2. Pressure compensated.
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1.Non-pressure-compensated flow-control valves Used when the system pressure is relatively constant
and motoring speeds are not too critical.
The operating principle behind these valves is that the
flow through an orifice remains constant if the pressure
drop across it remains the same.
Disadvantage-
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.
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Non-pressure-compensated flow-control valves: Cont….
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Pressure-compensated flow-control valve.Pressure compensated flow control valves are used to limit or
regulate flow.
P3 is conjunction with spring pressure causes downward force and
P2 causes upward force
Piston is moves up and down until pressure differential between P2
and P3 matched spring compressive force, hence termed as Pressure-
compensated flow-control valve
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Non-pressure-compensated flow-control valves
1. Gate ValveA valve that opens by lifting a round or rectangular gate/wedge out of
the path of the fluid.
The distinct feature of a gate valve is the sealing surfaces between the
gate and seats are planar, so gate valves are often used when a straight-
line flow of fluid and minimum restriction is desired.
Primarily used to permit or prevent the flow of liquids, but typical
gate valves shouldn't be used for regulating flow, unless they are
specifically designed for that purpose.
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Gate Valve
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2. Globe valve Used for regulating flow in a pipeline, consisting of a movable disk-type
element and a stationary ring seat in a generally spherical body.
Globe valves are used for applications requiring throttling and frequent
operation
They are not recommended where full, unobstructed flow is required.
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Globe valve
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Needle valveA type of valve having a small port and a threaded, needle-
shaped plunger.
It allows precise regulation of flow, although it is generally
only capable of relatively low flow rates.
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The solenoid valve is therefore acting much like
a switch in an electrical circuit.
In one position the light is switched off...
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... and in the other position it is switched
on but there are no intermediate states.
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However, another type of switch can be used
for controlling a light bulb known as a
dimmer switch.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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In this case, the switch can be turned to any
position between fully off and fully on to vary
the brightness of the bulb.
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SWITCHING SOLENOID VALVE
A conventional solenoid valve can be thought of
as a simple switching valve.
It is controlled by some form of electrical device
which simply switches the electrical current on
or off.
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SWITCHING SOLENOID VALVE
A conventional solenoid valve can be thought of
as a simple switching valve.
It is controlled by some form of electrical device
which simply switches the electrical current on
or off.
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SWITCHING SOLENOID VALVE
A conventional solenoid valve can be thought of
as a simple switching valve.
It is controlled by some form of electrical device
which simply switches the electrical current on
or off.
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PROPORTIONAL VALVE
A proportional directional valve however will
be controlled by an electrical device more
like a dimmer switch.
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PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied and
hence the amount of flow through the valve can
be controlled.
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PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied and
hence the amount of flow through the valve can
be controlled.
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PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied and
hence the amount of flow through the valve can
be controlled.
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PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied and
hence the amount of flow through the valve can
be controlled.
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PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied and
hence the amount of flow through the valve can
be controlled.
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PROPORTIONAL VALVE
By varying the current to either solenoid, the
amount of spool movement can be varied and
hence the amount of flow through the valve can
be controlled.
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LIFT EXAMPLE - CONVENTIONAL SYSTEM
The reason why it is useful to be able to control the speed of spool movement of a valve is to
reduce shock in a system. This is achieved by controlling the acceleration and deceleration of the
actuator. Suppose, for example, that the simple hydraulic system described earlier is used to operate
a passenger lift in a hotel.
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LIFT EXAMPLE - CONVENTIONAL SYSTEM
When the solenoid valve is energised to lower the lift, the valve spool will move across very
rapidly. This means that the cylinder will accelerate very quickly up to its maximum speed
(determined by the setting of flow control valve F). This sudden starting of the lift provides a very
uncomfortable ride for its occupants.
F
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LIFT EXAMPLE - CONVENTIONAL SYSTEM
Similarly, when the lift reaches its destination, the solenoid valve will shut off very rapidly causing
a sudden stopping of the lift and again a very uncomfortable situation for the occupants. In real
hydraulic systems, the shocks generated by sudden starting and stopping of actuators create high
peak pressures which are one of the principle causes of fluid leakage.
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LIFT EXAMPLE - PROPORTIONAL SYSTEM
If the solenoid valve and flow control valve are replaced with a proportional valve then not only
can the speed of the lift be adjusted electronically, but also its stopping and starting can be
controlled.
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LIFT EXAMPLE - PROPORTIONAL SYSTEM
The proportional valve can be opened sufficiently slowly to provide a smooth acceleration of the
lift up to its maximum speed.
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LIFT EXAMPLE - PROPORTIONAL SYSTEM
And likewise the deceleration can be controlled by slowing down the speed of spool movement
back to the centre condition.
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time
Dis
tan
ce
MOTION CONTROL
In general therefore, proportional valves are capable of providing full motion
control in terms of:
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time
Acceleration
Dis
tan
ce
MOTION CONTROL
1. A smooth and controlled acceleration of an actuator up to its maximum speed.
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time
Acceleration
Velocity
Dis
tan
ce
MOTION CONTROL
2. Control of the actuator velocity and if necessary maintaining it constant with
varying loads.
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time
Acceleration
Deceleration
Velocity
Dis
tan
ce
MOTION CONTROL
3. A smooth deceleration with minimal pressure peaks.
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time
Force
FORCE CONTROL
Proportional valves can also be
used to control the force output
from an actuator (for example
in press or plastic injection
moulding applications) by
controlling the pressure applied
to the actuator.
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time
Force
FORCE CONTROL
In such cases it is often
necessary to control not only
the maximum actuator pressure
but also the rate at which the
pressure is applied or removed.
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time
Force
FORCE CONTROL
In fact the machine cycle may
consist of a series of ramps and
holding periods all of which
can be achieved with just the
one proportional valve.
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time
Force
FORCE CONTROL
At the end of the machine cycle
the rate at which the pressure is
reduced is also critical in many
processes.
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FORCE CONTROL
Motion and force control can
thus be achieved using
proportional valves, and in
some cases the same valve can
be used for both motion and
force control. This is usually
referred to as ‘PQ’ control ie.
the control of both pressure (P)
and flow (Q).
Furthermore, all of these
control functions can be
achieved using electronic
inputs to the valve thus
providing a simple interface to
the machine controller.
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PROPORTIONAL CONTROL VALVES
Proportional control valves can be operated easily using a
solenoid.
Solenoid controls have a digital control system: A valve is
opened when the solenoid is energized and is closed when it is
de-energized or vice versa.
They are very quick in their operation and thus give rise to
pressure and flow surges in the fluid power control units
The advantage of these valves is that they give greater
flexibility in the system design and operation.
They also decrease fluid power circuit complexity especially
for processes requiring multiple speed or force outputs.
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Notched spool proportional valve.(a) Valve construction;(b) electrical control diagram
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Cartridge valves
The term cartridge valves commonly refers to pressure,
directional, and flow control valves that screw into a
threaded cavity.
These valves are mostly rated for low flows - 40 gpm or
less
They are available in many configurations; on/off,
proportional, pressure relief, etc. They generally screw into a
valve block and are electrically controlled to provide logic
and automated functions.
Advantages:1.Leakage problem minimum
2.Small size and light in weight
3.Operating noise level is less
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Pre-fill valve
Pre-fill valves operate similarly to pilot-operated check valves, but they are usually much larger.
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Their normal function is to fill and exhaust a large bore cylinder as it
travels to and from contact with the work piece. Large, high-tonnage
presses -- both vertical and horizontal -- use pre-fill valves to reduce
pump size while maintaining cycle time.
A large main-flow poppet seals the path between the tank and the
cylinder ports. As the piston advances, vacuum in the void behind it
allows atmospheric pressure to push the main-flow poppet open so
fluid from the tank can fill this void. On the retraction stroke, a signal
to the pilot piston pushes the main-flow poppet open so fluid can return
to tank. While a pilot-operated check valve’s pilot piston is larger than
the poppet it opens, the main-flow poppet in a pre-fill is much larger in
diameter than the pilot piston. Thus it is impossible to open the main-
flow poppet against high backpressure. This keeps decompression
shock from damaging pipes and components.
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The circuit in operates a vertical single-acting hydraulic ram press with pullback cylinders for the
retraction stroke. The press has a poppet-type pre-fill and gets a fast stroke from only filling the pullback
cylinders during the approach stroke. A sequence valve keeps pump flow from going to the ram until
pressure reaches a preset level.
During the approach part of the stroke, atmospheric pressure pushes fluid into the large-bore ram through
the pre-fill valve because there is vacuum behind the extending ram. When it contacts the work, the ram
stops and the pre-fill valve closes. Pressure starts to rise and when it is high enough to open the sequence
valve, pump flow goes to the pullback cylinders and the ram. Extension speed slows and tonnage increases
to do the work required.
A signal that the work is complete shifts the directional control valve to send pump flow to the rod ends of
the pullback cylinders and to the pilot signal of the pre-fill valve. The pre-fill valve’s pilot piston moves
forward and contacts the decompression poppet. This lets trapped fluid flow out at a controlled rate.
Pressure in the ram drops quickly and smoothly. When pressure is low enough, the pilot piston opens the
main poppet to let fluid from the ram return to tank. When the ram loses pressure, the pullback cylinders
can raise the platen and push fluid from the ram back to tank.
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Brake valve
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A brake valve performs the same function as a counterbalance valve, but it is designed to
overcome a key disadvantage . The pressure drop across the counterbalance valve is converted
to heat; consequently, half the hydraulic power is wasted.
A brake valve has an internal pilot passage and a remote pilot passage. Suppose the spring is
set for 1000 psi. When pressure at the internal pilot reaches 1000 psi, the piston pushes the
spool upward to open the valve.
The area of the piston is much less than the area of the bottom of the spool. A typical area ratio
might be 10:1. The remote pilot applies pressure directly to the bottom of the spool;
consequently, only 100 psi is required to compress the spring and open the valve. Pressure
required to open the valve is 1000 psi at the internal pilot and 100 psi at the remote pilot.
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It requires 100 psi at the motor inlet to keep the valve open. As long asthe load on the motor requires more than 100 psi, the brake valve doesnot affect circuit efficiency. If the load starts to overrun, and the pressuredrops below 100 psi, the brake valve closes. It requires 1000 psi at thedirect (or internal) pilot to open the valve. This 1000-psi pressure dropacross the brake valve converts the mechanical energy of the overrunningload to heat energy and slows the load. When pressure at the inlet buildsto 100 psi again, the brake valve opens
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Hydraulic Servo valves
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The hydraulic systems, subsystems and hydraulic components that have been discussed so far have
had open-loop control or in other words power transfer without feedback. We shall now take a
look at servo or closed loop control coupled with feedback sensing devices, which provide for a
very accurate control of position, velocity and acceleration of an actuator.
A servo valve is a direction control valve, which has an infinitely variable positioning capability.
Thus, it controls not only the direction of the fluid flow but also the quantity. In a servo valve, the
output controlled parameter is measured with a transducer and fed back to a mixer where the
feedback is compared with the command. The difference is expressed in the form of an error
signal which is in turn used to induce a change in the system output, until the error is reduced to
zero or near zero. A typical example is the use of a thermostat in an automatic furnace whose
function is to measure the room temperature and accordingly increase or decrease the heat in
order to keep it constant. Let us now discuss in brief, the various components that comprise a
servo system.
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This valve is essentially a mechanical force amplifier used for positioning control. In this
design, a small impact force shifts the spool by a specified amount. The fluid flows through
port P o retracting the hydraulic cylinder to the right. The action of the feedback link shifts
the sliding sleeve to the right until it blocks off the flow to the hydraulic cylinder. Thus, a
given input motion produces a specific and controlled amount of output motion. Such a
system where the output is fed back to modify the input, is called a closed loop system.
One of the most common applications of this type of mechanical hydraulic servo valve is in
the hydraulic power steering system of automobiles and other transport vehicles.