Hydraulic Systems

Lecture 3
Control Valves 1
In a hydraulic system, the hydraulic energy available from a pump is converted into motion and force
by means of an actuator. The control of these mechanical outputs (motion and force) is one of the
most important functions in a hydraulic system. The proper selection of control selection ensures the
desired output and safe function of the system. In order to control the hydraulic outputs, different
types of control valves are required. It is important to know various types of control valves and their
functions. This not only helps to design a proper hydraulic system but also helps to discover the
innovative ways to improve the existing systems. In this lecture and next few lectures, various types
of valves will be discussed.
There are basically three types of valves employed in hydraulic systems:
1. Directional control valves
2. Flow control valves
3. Pressure control valves

1. Direction control valve

Directional control valves are used to control the distribution of energy in a fluid power system. They
provide the direction to the fluid and allow the flow in a particular direction. These valves are used to
control the start, stop and change in direction of the fluid flow. These valves regulate the flow
direction in the hydraulic circuit. These control valves contain ports that are external openings for the
fluid to enter and leave. The number of ports is usually identified by the term ‘way’. For example, a
valve with four ports is named as four-way valve. The fluid flow rate is responsible for the speed of
actuator (motion of the output) and should controlled in a hydraulic system. This operation can be
performed by using flow control valves. The pressure may increase gradually when the system is
under operation. The pressure control valves protect the system by maintaining the system pressure
within the desired range. Also, the output force is directly proportional to the pressure and hence, the
pressure control valves ensure the desired force output at the actuator.

Directional control valves can be classified in the following manner:

1. Type of construction:
• Poppet valves
• Spool valves

2. Number of ports:
• Two- way valves
• Three – way valves
• Four- way valves.

3. Number of switching position:

• Two – position
• Three - position

4. Actuating mechanism:
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• Manual actuation
• Mechanical actuation
• Solenoid actuation
• Hydraulic actuation
• Pneumatic actuation
• Indirect actuation

1.1 Type of construction

1.1.1 Check Valves

Spring
Flow blocked

Ball

Flow allowed
Figure 1: Inline check valve

These are unidirectional valves and permit the free flow in one direction only. These valves have two
ports: one for the entry of fluid and the other for the discharge. They are consists of a housing bore in
which ball or poppet is held by a small spring force. The valve having ball as a closing member is
known as ball check valve. The various types of check valves are available for a range of applications.
These valves are generally small sized, simple in construction and inexpensive. Generally, the check
valves are automatically operated. Human intervention or any external control system is not required.
These valves can wear out or can generate the cracks after prolonged usage and therefore they are
mostly made of plastics for easy repair and replacements.

An important concept in check valves is the cracking pressure. The check valve is designed for a
specific cracking pressure which is the minimum upstream pressure at which the valve operates. The
simplest check valve is an inline check valve as shown in Figure.1. The ball is held against the valve
seat by a spring force. It can be observed from the figure that the fluid flow is not possible from the
spring side but the fluid from opposite side can pass by lifting the ball against. However, there is some
pressure drop across the valve due to restriction by the spring force. Therefore these valves are not
suitable for the application of high flow rate. When the operating pressure increases the valve
becomes more tightly seated in this design.

The advantages of the poppet valves include no leakage, long life and suitability with high pressure
applications. These valves are commonly used in liquid or gel mini-pump dispenser spigots, spray
devices, some rubber bulbs for pumping air, manual air pumps, and refillable dispensing syringes.
Sometimes, the right angle check valve as shown in Figure 2 is used for the high flow rate
applications. The pressure drop is comparatively less in right angle check valve.

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 Figure 2 Right angle check valve

When the closing member is not a ball but a poppet energized by a spring is known as poppet valve.
The typical poppet valve is shown in Figure 3. Some valves are meant for an application where free
flow is required in one direction and restricted flow required in another direction. These types of
valves are called as restriction check valve (see Figure.3). These valves are used when a direction
sensitive flow rate is required. For example, the different actuator speeds are required in both the
directions. The flow adjustment screw can be used to set the discharge (flow rate) in the restricted
direction.

Figure 3: Restriction check valve

Another important type of check valve known as pilot operated check valve which is shown in figure
4. The function of the pilot operated check valve is similar to a normal check valve unless it gets an
extra pressure signal through a pilot line. Pilot allows free flow in one direction and prevents the flow
in another direction until the pilot pressure is applied. But when pilot pressure acts, the poppet opens
and the flow is blocked from both the sides. These valves are used to stop the fluid suddenly.

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 Figure 4: Pilot operated check valve

1.1.2 Spool valve

The spool valves derive their name from their appearance. It consists of a shaft sliding in a bore which
has large groove around the circumference. This type of construction makes it look like a spool. The
spool is sealed along the clearance between moving spool and housing (valve body). The quality of
seal or the amount of leakage depends on the amount of clearance, viscosity of fluid and the level of
the pressure. The grooves guide the fluid flow by interconnecting or blocking the holes (ports). The
spool valves are categorized according to the number of operating positions and the way hydraulic
lines interconnections. One of the simplest two way spool valve is shown in Figure 5. The standard
terms are referred as Port ‘P’ is pressure port, Port ‘T’ is tank port and Port ‘A’ and Port ‘B’ are the
actuator (or working) ports. The actuators can move in forward or backward direction depending on
the connectivity of the pressure and tank port with the actuators port.

Figure 5 Valve closed

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 Figure 6 Valve opened by actuation

1.2 Number of ports

1.2.1 Two way valves

Two way valves have only two ports as shown in Figure 5 and Figure 6. These valves are also known
as on-off valves because they allow the fluid flow only in direction. Normally, the valve is closed.
These valves are available as normally open and normally closed function. These are the simplest type
of spool valves. When actuating force is not applied to the right, the port P is not connected with port
A as shown in figure 5. Therefore, the actuation does not take place. Similarly, Figure .6 shows the
two-way spool valve in the open condition. Here, the pressure port P is connected with the actuator
port A.

1.2.2 Three way valves

When a valve has one pressure port, one tank port and one actuating port as shown in Figures 7 and 8,
it is known as three way valve. In this valve, the pressure port pressurizes one port and exhausts
another one. As shown in figures, only one actuator port is opened at a time. In some cases a neutral
position is also available when both the ports are blocked. Generally, these valves are used to operate
single acting cylinders.

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 Figure 7 Three way valve: P to A connected and T is blocked

Figure 8 Three way valve in closed position

1.2.3 Four way valves

Figure 9 shows a four-way valve. It is generally used to operate the cylinders and fluid motors in both
the directions. The four ways are: pump port P, tank port T, and two working ports A and B connected
to the actuator. The primary function of a four way valve is to pressurize and exhaust two working
ports A and B alternatively.

Figure 9 Three position four way valve in open center mode

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