Fluid Power Diagrams and Questions (Mechanical engineering Pneumatic & hydraulic)

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MODULE TITLE : APPLICATIONS OF PNEUMATICS AND

HYDRAULICS

TOPIC TITLE : FLUID POWER DIAGRAMS

LESSON 5 : HYDRAULIC PRESSURE CONTROL VALVES

APH - 1 - 5

Published by Teesside University Open Learning (Engineering)

School of Science & Engineering

Teesside University

Tees Valley, UK

TS1 3BA

+44 (0)1642 342740

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________________________________________________________________________________________

INTRODUCTION ________________________________________________________________________________________

The control element of a hydraulic system is provided by the system's valves.

In this lesson and the next we will examine hydraulic valves, and illustrate

their many functions.

Hydraulic valves are used to control system pressure, flow rate and direction of

flow. Here we will deal only with pressure-control valves.

________________________________________________________________________________________

YOUR AIMS ________________________________________________________________________________________

On completion of this lesson you should be able to:

• differentiate between a direct acting and a compound design of

pressure relief valve

• describe the function of a relief valve, a safety valve, a sequence

valve, a pressure-reducing valve, unloading and off-loading valves,

as well as counterbalance and brake valves

• identify these components on a hydraulic diagram from their

symbolic representation to BS 2917.

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________________________________________________________________________________________

HYDRAULIC VALVES ________________________________________________________________________________________

Valves are used in a hydraulic system to control the hydraulic power delivered

by the system pump which is driven by the prime mover.

• They will control the force or torque that can be exerted by an

actuator, by controlling the pressure of the fluid supplied to it.

• They will control the speed at which the actuator moves, by

controlling the flow rate of the fluid being supplied to it.

• They will also be used to control the direction in which the actuator

will move, by diverting fluid from one actuator port to another, so

controlling the direction of fluid flow through the actuator.

PRESSURE-CONTROL VALVES

One of the most important pressure-control valves is the relief valve or safety

valve. Its prime function is to limit system pressure.

Relief valves usually establish or limit a working pressure. Safety valves

operate only when there is a circuit malfunction. A relief valve may, however,

operate in a dual capacity, as both relief valve and safety device.

Relief valves are usually sited as close to the pump outlet as possible, and

come in two basic designs. FIGURE 1 shows the constructional details of the

direct-acting relief valve, along with its symbolic representation to BS 2917.

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FIG. 1 Direct-Acting Relief Valve

The direct-acting relief has two port connections, the inlet which is connected

to system pressure (P), and the outlet usually connected to the tank (T). The

valve is a normally-closed valve, with the system pressure being opposed by a

poppet or a ball, held firmly on a valve seat by an adjustable spring. When the

pressure of the fluid, acting on the poppet or ball area exposed to it, can exert

sufficient force to push the poppet off the valve seat, fluid will flow through

the valve back to the tank at low pressure.

When fully open, the valve will divert all of the pump flow back to the tank,

and prevent the system pressure from rising any higher than the fully-open

setting of the valve.

The adjusting screw is used to increase or decrease the pressure at which the

valve will start to open. The pressure at which the valve just opens is

described as its 'cracking pressure', and the system pressure when the valve is

fully open is called the 'full flow pressure'. The difference between full flow

and cracking pressures is called 'pressure override': this may be as much as

P T

T Adjusting screw

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10% of the full flow pressure of the valve. This means that, if the full flow

pressure of the valve is set at 200 bar, the valve may actually start leaking fluid

at 180 bar, with a subsequent loss in hydraulic power.

In some hydraulic systems, where the valve is being used primarily as a safety

valve, this loss of power is not important. However, in other systems, losses

due to pressure override do interfere with the efficient operation of the

machine, and cannot be tolerated.

Pressure override tends to increase as heavier valve springs are used.

Therefore, in an attempt to reduce pressure override to a negligible value, the

compound relief or pilot-operated relief valve was designed. This valve does

not rely on heavy springs for its operation, therefore pressure override is

negligible.

FIGURE 2 illustrates the constructional details of a compound relief valve,

along with its hydraulic symbol to BS 2917.

The compound relief valve is a two-stage valve. The operating pressure is set

by adjusting the setting of the pilot relief valve. The main relief valve has a

spool with a drilled orifice: fluid can pass through this orifice, and create a

pressure balance across the main spool. This means that, provided that fluid

does not flow through the pilot relief, the main spool can be held closed by a

relatively light spring. However, if the pilot valve is opened, by the system

reaching the set pressure, then, the pressure balance cannot be achieved, and

the main valve opens to divert the full pump flow to tank.

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FIG. 2 Compound Relief Valve

Because this design of relief valve does not use heavy-duty springs in its operation, the amount of pressure override is negligible.

What do you think will be the effect on the operation of a hydraulic system, if the

system pressure relief valve malfunctions and jams in the fully open state?

....................................................................................................................................................

__________________________________________________________________________________________________

∆ P

Pilot stage

Vent port plug

Main valve spool

P T

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This will allow the total output from the pump to flow unopposed directly to tank. As there

is now no resistance to flow in the system, there will be no rise in pressure, and no work can

be done by the system.

Relief Valve Unloading

The compound relief valve can also be connected to a directional valve; the

operation of this valve will vent the pressure on the top of the main spool, and

allow the valve to come open at a minimal pressure. This has the effect of

dumping the flow from the pump at minimal pressure, and allowing it to run in

an unloaded state.

The unloading valve can be operated manually, electrically or by a fluid

pressure signal. FIGURE 3 illustrates the principle using a solenoid-operated

vent valve V. This method is commonly used to allow the system pump to

always start under light-load conditions, and allows the system to be fitted with

a smaller prime mover as a consequence.

The motor-start control will energise a timing relay which, in turn, will

energise the vent valve to unload the main relief. After 5 or 10 seconds, when

the motor has run up to full speed, the solenoid is de-energised: the system can

then load up to normal working pressure.

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FIG. 3 Venting a Compound Relief Valve

Off-loading Valve

The off-loading valve is a remotely-controlled relief valve, normally used in

conjunction with double-pump circuits. In FIGURE 4 a double-pump unit is

driven by a common electric motor. Pump A is a high pressure, small capacity

unit: pump B is a low pressure unit of high capacity. The off-loading valve is

∆ P

Vent valve

To system

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connected into the supply from the low-capacity pump, but piloted by a signal

emanating from the output from the high-pressure pump. Maximum system

pressure is controlled by the conventional relief valve, connected to the output

from the high-pressure pump.

FIG. 4 Pump Off-loading

When the pressure in the system rises to 50 bar, the off-loading valve is opened

by the pilot pressure. The output from the low-pressure pump is diverted to

the tank at minimal pressure. This reduces the work load on the pump drive

motor and allows this extra capacity to be used to drive the high-pressure

pump up to the maximum system operating pressure of 200 bar.

As the pressure in the system falls to below 50 bar, the off-loading valve will

be closed, and the output from the low-pressure pump will once again be

delivered into the system.

To system

50 bar 200 bar

Off-loading valve symbol

P T

Pump BPump A

LPMHP

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In the system shown in FIGURE 4, what prevents the decay of system pressure

occurring when the off-loading valve is opened by the pilot control?

....................................................................................................................................................

__________________________________________________________________________________________________

The non-return check-valve situated in the low pressure pump output line, downstream of

the off-loading valve, will prevent pressure decay.

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Sequence Valves

A sequence valve is another normally-closed pressure-control valve, very

similar in design to a relief valve. It will allow the hydraulic fluid to flow into

a sub-circuit, when the pressure in the main system has reached the setting of

the sequence valve. By this method, it is possible to control the sequence of

events in a hydraulic control system.

FIGURE 5 shows how the operational sequence of two hydraulic actuators can

be controlled using a sequence valve.

FIG. 5 Sequence Circuit

–

– +

30 bar

A B

P T

A B

Sequence valve with integral reverse flow check and

external drain connection

Direction control valve

70 bar

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When the directional valve is energised P to A, fluid will be diverted into the

head end of cylinder A and to the inlet port of the sequence valve. The

cylinder A will extend and, when resistance to motion causes the system

pressure to rise (in this case to 30 bar), then the sequence valve will open to

allow flow to enter the rod end of cylinder B, causing this cylinder to retract.

When the directional valve is energised P to B, then fluid will be diverted to

the rod end of cylinder A and to the head end of cylinder B. This will cause

both cylinders to reverse their previous operation, with the exhaust flow from

the rod end of cylinder B passing through the sequence valve, via the integral

reverse-flow check valve. The operational sequence of the above circuit is

therefore:

A + B – (A – B+)

Which unit in the above circuit (FIGURE 5) is responsible for establishing the

maximum pressure that can be applied to the actuators?

....................................................................................................................................................

__________________________________________________________________________________________________

The maximum pressure that can develop in this system will ultimately be controlled by the

system relief valve (in this case set at 70 bar).

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Pressure-Reducing Valve

Pressure-reducing valves are the only normally-open pressure-control valves.

Their function is to limit the pressure downstream of the valve to a value less

than the pressure upstream of the valve.

The circuit shown in FIGURE 6 shows a clamp and stamp circuit that utilises

two hydraulic cylinders. The operating sequence of the cylinders is controlled

by the sequence valve which will allow the clamp cylinder to outstroke before

the stamping cylinder.

However, in this particular case, clamp pressure must be limited by a pressure

reducing valve to prevent damage to the component by the action of the clamp.

With the directional control valve in the position shown, system fluid will pass

through the valve and into the clamping cylinder via the pressure-reducing

valve. The clamp cylinder will outstroke to clamp the component. The

pressure-reducing valve will limit the pressure build-up on the full bore end of

the cylinder to 50 bar (its set value).

Pressure upstream of the reducing valve will rise initially to 60 bar at which

time the sequence valve will open to allow fluid to flow into the full bore end

of the stamp cylinder. The maximum stamping pressure can rise to the setting

of the system relief valve (100 bar). Reversal of the directional control valve

will instroke both cylinders almost simultaneously, with fluid being evacuated

from the full bore ends of both cylinders via the reverse flow checks of both

the sequence and pressure-control valves.

Although the pressure-reducing valve is a normally-open valve, reverse flow

through the valve is only possible if the pressure in the subcircuit is less than

the set pressure of the valve. If the reverse flow pressure exceeds the valve

setting, the valve will be forced closed and reverse flow will be impossible. In

such cases, it is usual to use a valve with an integral reverse flow check.

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FIG. 6 Sequence Circuit

In the illustration (FIGURE 6) the pressure-reducing valve has a connection to tank

(T). What do you think is the purpose of this connection?

....................................................................................................................................................

__________________________________________________________________________________________________

Clamp Stamp

60 bar50 bar

100 bar Pressure reducing

valve

Sequence valve

Pressure Reducing Valve with integral reverse flow check

A B

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Answer

The connection to tank on the pressure-reducing valve is an external drain port.

In the case of this particular valve, with it being of compound design, the pilot

fluid, which would normally travel down the centre of the spool to the outlet of

the valve, cannot do so. This is because the outlet is pressurised and it would

cause a malfunction of the valve. It is therefore necessary to drain this oil

directly back to the tank using a separate line.

Counterbalance and Brake Valves

A counterbalance valve is a normally-closed valve, similar in design to a relief

valve. It is used to create a back pressure on the underside of a vertically

mounted piston, to prevent a suspended load from falling freely, due to gravity,

when being hydraulically lowered.

The circuit shown in FIGURE 7 illustrates the functional operation of a

counterbalance valve.

The pressure setting of the counterbalance is slightly higher than that required

to prevent the load from falling freely.

Therefore, to lower the load, we require hydraulic assistance: thus fluid is

supplied to the head end of the cylinder. The combined efforts of the

suspended load and the pressure applied to the cylinder will be sufficient to

force the counterbalance valve open, and the load will start to lower. Any

tendency to fall freely is counteracted by the valve.

When the load needs to be raised, the directional valve is operated to divert the

fluid flow through the reverse-flow check of the counterbalance valve, and into

the rod end of the cylinder.

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FIG. 7 Circuit with Counterbalance

What do you think would be the effect on the operation of the system in FIGURE 7, if

the suspended mass was removed from the end of the cylinder rod?

....................................................................................................................................................

__________________________________________________________________________________________________

100 bar

Mass

Counterbalance valve

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Answer

Removing the suspended mass would affect the operating pressures. The

cylinder would retract at a much lower pressure than before, because there was

no longer a load to be lifted. However, the cylinder would require a far higher

pressure to extend, because it would have to overcome the resistance to flow,

created by the counterbalance valve without the assistance of the mass.

A brake valve is very similar to a counterbalance valve, but is normally sited in

the exhaust line of a hydraulic motor. Its function is to prevent the motor from

overspeeding, when an overrunning load is applied to the motor shaft, and to

provide a smooth rate of deceleration. See FIGURE 8.

FIG. 8

Brake valve

A B

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When the motor is to be run in its normal direction of rotation, the directional

valve is actuated to provide flow into the motor inlet port. As well as

supplying oil to the motor, it will also feed to the cross-line pilot connection of

the brake valve (X). This will cause the valve to open at a much lower value

than the valve is set for, sometimes as little as 10% of the preset pressure.

The flow of fluid will cause the motor to rotate, and exhaust flow will return to

tank, via the pilot-opened brake valve and the directional valve.

Any tendency for the motor to overspeed, due to an overunning load, will

result in a reduction in inlet pressure, and the collapse of the pilot signal (x).

The brake valve will then impose its preset back-pressure, sensed by the

internal pilot, on the exhaust flow which will reduce the running speed of the

motor. As the motor speed drops, the flow resistance in the inlet line will

increase, causing the pressure to increase, re-establishing the pilot signal (x).

This now removes the back-pressure braking.

When the motor is to be stopped, the directional valve is moved to its central

off condition, which removes the supply from the motor inlet and cross-line

pilot. The brake valve once again imposes back-pressure braking, to bring the

motor to a smooth controlled stop. If reverse rotation of the motor drive is

required, it is usual for the brake valve to be fitted with an integral reverse-

flow check-valve.

That concludes this lesson on pressure-control valves. All of the valves

discussed are very similar to each other. In many cases, it is only by looking at

the application of the valve that we can identify it.

Now answer the Self-Assessment Questions on the next page.

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________________________________________________________________________________________

SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________

1. What are the three features controlled by valves in a hydraulic system?

2. What are the two general types of relief valve called?

3. What is the function of an unloading valve?

4. What is the function of a sequence valve?

5. Use BS 2917 symbols to represent a double-pump system with low

pressure pump off-loading.

6. What is the function of a counterbalance valve?

7. Draw the symbolic representation of a pressure-reducing valve, complete

with an integral reverse-flow check-valve.

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________________________________________________________________________________________

NOTES ________________________________________________________________________________________

...................................................................................................................................................

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________________________________________________________________________________________

ANSWERS TO SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________

1. The three features controlled by the valves in a hydraulic system are

pressure, flow rate and direction of flow.

2. The two general designs of relief valve are:

• direct-acting relief valve

• compound or pilot-operated relief valve.

3. An unloading valve is used to permit the pump to operate at minimum

load, by overriding the system relief valve and diverting fluid flow

directly to the tank at minimal pressure.

4. The function of a sequence valve is to control the sequence of events in a

hydraulic system, by opening at an adjustable preset pressure, to allow

fluid to flow into the system sub-circuits at the desired time in the

operational cycle.

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FIG. 4 (Reproduced)

6. The function of a counterbalance valve is to maintain a constant back-

pressure in the system, to prevent a suspended load from falling freely,

due to the effects of gravity when being hydraulically lowered.

Pressure reducing valve with integral reverse

flow check

To system

50 bar 200 bar

Off-loading valve symbol

P T

Pump BPump A

LPMHP

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________________________________________________________________________________________

SUMMARY ________________________________________________________________________________________

In this lesson we have looked at the uses of pressure-control valves in a

hydraulic system. Pressure on the actuator will control its output force: the

system relief valve will set the maximum pressure in a hydraulic system.

However, we can use pressure-control valves to control other features of a

hydraulic system, not only maximum system pressure. Unloading and off-

loading valves will reduce the workload on the system prime mover. Sequence

valves will control the operational sequence of the system: counterbalance and

brake valves are used to provide back-pressure braking on system actuators.

Pressure-reducing valves are used to limit pressure in system sub-circuits to a

value less than the main system pressure: they are the only normally-open

pressure-control valves

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setdistillerparams << /HWResolution [2400 2400] /PageSize [612.000 792.000] >> setpagedevice