DIRECTIONAL CONTROL VALVE

Bang-bang is the term often used to describe basic directional-control

valves. It refers to how the valves shift—from completely open to completely
closed. This usually occurs in an instant, causing fluid to rapidly accelerate and
decelerate. Under certain conditions, this can cause fluid hammer, which sounds
like a hammer striking the hydraulic system from inside. Hence, shifting the
valve from one position to another can produce a bang-bang sound. A less-
informal term to describe these components is discrete valves. This term refers
to how the valves operate: They shift from one discrete position to another, such
as extend, retract, and neutral. Proportional valves, on the other hand, control
direction and speed. In addition to shifting into discrete positions, they can shift
into intermediate positions to control actuator direction, speed, acceleration, and
deceleration.
 Even more basic than the discrete directional-control valve is the binary
valve. As in digital electronics, binary valves operate either on or off. Whereas
discrete valves generally use a spool to achieve two, three, or more positions,
discrete valves use a plunger, poppet, or ball that seals against a seat. The
advantage to this type of operation is that it provides a positive seal to prevent
cross-port leakage.

Perhaps the simplest of all directional-control valves is the check valve, a

specific type of binary valve. Basic check valves allow fluid to flow in one
direction but prevent fluid from flowing in the opposite direction. As with all
fluid power components, directional-control valves can be represented by
standard symbols published in ISO 1219. Figure shows a cross-section of a
spring-loaded check valve and its ISO 1219 representation.

Basic check valve allows fluid to flow in one direction, in this case from
bottom to top. Shown are ISO symbol and cross-sectional photo of spring-
loaded check valve. The spring keeps fluid from flowing unless downstream
pressure acting on the poppet overcomes spring force.

PORTS AND POSITIONS

The two primary characteristics for selecting a directional-control valve

are the number of fluid ports and the number of directional states, or positions,
the valve can achieve. Valve ports provide a passageway for hydraulic fluid to
flow to or from other components. The number of positions refers to the number
of distinct flow paths a valve can provide.

A 4-port, 3-position spool valve serves as a convenient illustration. One

port receives pressurized fluid from the pump, and one routes fluid back to the
reservoir. The other two ports are generally referred to as work ports and route
fluid to or from the actuator. In this case, one work port routes fluid to or from
the rod end of the cylinder, the other routes fluid to or from the cap end.

The valve represented in Fig can be shifted to any of three discrete

positions. As shown, in the neutral position, all ports are blocked, so no fluid
will flow. Shifting the valve to the right routes fluid from the pump to the rod
end of the cylinder, causing its piston rod to retract. As the piston rod retracts,
fluid from the cylinder's cap end flows to the reservoir. Shifting the valve to the
left routes fluid from the pump to the cap end of the cylinder, causing the piston
rod to extend. As this occurs, fluid from the rod end of the cylinder flows to the
reservoir. Returning the valve spool to the center position again blocks all flow.

Schematic shows simple circuit to control cylinder extension and retraction

using a 4-port, 3-position spool valve.

Spool-type valves are widely used because they can be shifted to two,
three, or more positions for routing fluid between different combinations of inlet
and outlet ports. They are used extensively for directional control of actuators
because a single valve can produce extension, retraction, and neutral. However,
these same functions can be accomplished with binary valves. Figure 3 shows
four normally closed (NC) binary valves grouped into a hydraulic integrated
circuit to provide the same functionality as the spool valve

Arranging binary valves into a hydraulic integrated circuit allows them to

accomplish the same functions as discrete spool-type valves while retaining the
advantages of binary valves.

However, an important distinction must be made between binary

hydraulic and electric switches. When an electric switch is closed, a switching
element allows electrical current to flow through the switch. When the switch is
open, the electrical path is interrupted, so current cannot flow. In contrast, when
a hydraulic valve is open, it allows fluid to flow. When it is closed, fluid cannot
flow because its flow path is blocked.

Valve Operators

Valve operators are the parts that apply force to shift a valve’s flow-
directing elements, such as spools, poppets, and plungers. The sequence, timing,
and frequency of valve shifting is a key factor in fluid power system
performance. As long as the operator produces enough force to shift the valve,
the system designer can select any appropriate operator for the conditions and
type of control under which the system will operate.

Operators for directional-control valves are either mechanical, pilot,

electrical, and electronic, or a combination of these. Different types of actuators
can all be installed on the same basic valve design. A common directional valve
often is used that makes provision for mounting a variety of different operators
on its body.

With a mechanical operator, a machine element or person applies force

on the valve’s flow-directing element to move or shift it to another position.
Manual operators include levers, palm buttons, push buttons, and pedals. Purely
mechanical operators include cams, rollers, levers, springs, stems, and screws.
Springs are used in most directional valves to hold the flow-directing element in
a neutral position. In 2-position valves, for example, springs hold the non-
actuated valve in one position until an actuating force great enough to compress
the spring shifts the valve. When the actuating force is removed, the spring
returns the valve to its original position. In 3-position valves, two springs hold
the non-actuated valve in its center position until an actuating force shifts it.
When the actuating force is removed, the springs re-center the valve, leading to
the common identification, spring-centered valve. Detents are locks that hold a
valve in its last position after the actuating force is removed until a stronger
force is applied to shift the valve to another position. The detents may then hold
this new position after the actuating force again is removed.

Mechanical operation is probably the most positive way to control

industrial fluid power equipment. If a valve must shift only when a machine
element is in a certain position, the equipment can be designed so that the
machine element physically shifts the valve through a mechanical operator
when the element reaches the correct position. This arrangement virtually
eliminates any possibility of false or phantom signals from shifting the valve at
the wrong time.

However, mounting mechanically operated valves on a machine requires

some special cautions. The valve and actuator may be exposed to a wet or dirty
environment that requires special sealing. The actuator will probably be
subjected to impact loads, which must be limited to avoid physical damage.
Valve alignment with the operating element also is important, so the valve must
be mounted accurately and securely for long service life.

Pilot-actuated valves are shifted by pressurized fluid (often about 50

psig) that applies force to a piston that shifts the valve’s flow-directing
elements. An important advantage of pilot operation is that large shifting forces
can be developed without the impact and wear that affects mechanically
actuated valves. Pilot-operated valves can be mounted in any convenient or
remote location to which pressure fluid can be piped. The absence of sparks and
heat buildup makes pilot-actuated valves attractive for applications in
flammable or explosive environments.

Electric or electronic valve operation involves energizing a solenoid.

The force generated at the solenoid plunger then shifts the valve’s flow-
directing element. Solenoid-actuated valves are particularly popular for
industrial machines because of the ready availability of electric power in
industrial plants. However, mobile equipment makes extensive use of solenoid-
operated valves as well. The selection of ac or dc solenoids depends on the form
of electrical power available. At one time dc solenoids offered longer service
life, but improvements in ac solenoid designs have eliminated that advantage.

There is a practical limit to the force that solenoids can generate. This
means they cannot directly shift valves requiring high shifting forces.
Furthermore, valves using large solenoids also consume substantial electrical
power when valves must remain actuated for long intervals. Heat buildup can
also pose problems in these situations. The solution is to use small, low-power
solenoids in combination with pilot pressure. The solenoid starts and stops pilot
flow, and pilot pressure provides the high force to shift the valve’s flow-
directing mechanism.