APPLIED HYDRAULICS AND PNEUMATICS

Control components in Hydraulic system

One of the most important functions in any fluid power system is control. If control
components are not properly selected, the entire system will fail to deliver the required
output. Elements for the control of energy and other control in fluid power system are
generally called “Valves”. It is important to know the primary function and operation of
the various types of control components. This type of knowledge is not only required for
a good functioning system, but it also leads to the discovery of innovative ways to
improve a fluid power system for a given application
The selection of these control components not only involves the type, but also the
size, the actuating method and remote control capability. There are 3 basic types of
valves.
1. Directional control valves
1. Pressure controlvalves
2. Flow controlvalves.
Directional control valves are essentially used for distribution of energy in a fluid
power system. They establish the path through which a fluid traverses a given circuit. For
example they control the direction of motion of a hydraulic cylinder or motor. These
valves are used to control the start, stop and change in direction of flow of pressurized
fluid.
Pressure may gradually buildup due to decrease in fluid demand or due to sudden
surge as valves opens or closes. Pressure control valves protect the system against such
overpressure. Pressure relief valve, pressure reducing, sequence, unloading and
counterbalance valve are different types of pressure controlvalves.
In addition, fluid flow rate must be controlled in various lines of a hydraulic circuit.
For example, the control of actuator speeds depends on flow rates. This type of control is
accomplished through the use of flow control valves.

Directional control valves

As the name implies directional control valves are used to control the direction of
flow in a hydraulic circuit. They are used to extend, retract, position or reciprocate
hydraulic cylinder and other components for linear motion. Valves contains ports that are
external openings for fluid to enter and leave via connecting pipelines, The number of
ports on a directional control valve (DCV ) is usually identified by the term “ way”.For
example, a valve with four ports is named as four-way valve.

Directional control valves can be classified in a number of ways:

1. ccording to type of construction:

• Poppetvalves
• Spoolvalves
2. According to number of working ports:
• Two- wayvalves
• Three – wayvalves
• Four- wayvalves.
3. According to number of Switchingposition:
• Two –position
• Three -position
4. According to Actuatingmechanism:
• Manualactuation
• Mechanicalactuation
• Solenoid ( Electrical )actuation
• Hydraulic ( Pilot )actuation
• Pneumaticactuation
• Indirectactuation
The designation of the directional control valve refers to the number of working
ports and the number of switching positions.
Thus a valve with 2 service ports and 2 switching positions is designated as 2 /2
wayvalve. A

Fig 4.1. 2 /2 valve symbol

A valve with 3 service ports and 2 position is designated as 2 / 3 way valve.
A

P T
Fig 4.2. 2 / 3 valve symbol

A valve with 4 service ports and 2 position is designated as 2 / 4 valve.

A B

P T
Fig4.3. 2 / 4 valvesymbol

A valve with 4 Service ports and 3 Switching position is designated as 3 / 4 way

valve. Fig 4 shows an example of open centered position.
A B

P T
Fig4.4. 3/ 4 valve symbol:

Spool positions as well as their corresponding actuating elements are labelled

with numbers 1, 2 as shown in figure 5. A valve with 2 spool position is shown and
also a valve with 3 spool positions. In directional control valves with 3 spool position,
the central position is the neutral position ( ormid position or zero or null position ).
The neutral position is the position in which the moving parts are assumed to be
inactive, but affected by a force (e.g. spring )
The ports are designated asfollows:
P = Pressure Port ( Pump Port )
T = TankPort
A , B = UserPorts

1 2 1 0 2

2-Positionvalve 3- Positionvalve
Fig 4.5. Basic symbol for directional control valves
Observe that the graphical symbol shows only one tank port T even though
the physical design may have two since it is only concerned with the function of a
component and not its internal design. The tank port is the port of the valve that is piped
back to the hydraulic oil tank. Therefore, each tank port provides the same function. The
spool valve working ports are inlet from the pump, outlets to the cylinder, and exhaustto
tank. These ports are generally identified as follows : P = pressure ; A or B = actuator
and T =tank.
1. Poppet Valves: Directional poppet valves consists of a housing bore in which one
or more suitably formed seating elements ( moveable ) in the form of balls, cones
are situated. When the operating pressure increases the valve becomes more tightly
seated in this design. The main advantage of poppet valvesare;
- No Leakage as it provides absolutesealing.
- Long useful life, as there are no leakage of oilflows.
- May be used with even the highest pressures, as no hydraulic sticking (pressure
dependent deformation ) and leakages occurs in thevalve.
The disadvantages of these valves are;
- Large pressure losses due to shortstrokes
- Pressure collapse during switching phase due to negative overlap ( connection of
pump, actuator and tank at the same time).
2 / 2 DCV (Poppet design):-

A A

P
P

a. ValveClosed b. ValveOpened
 Fig4.6. 2 / 2 DCV PoppetDesign
Figure 4.6a. shows a ball poppet type 2 / 2 DCV. It is essentially a check valve as
it allows free flow of fluid only in one direction (P to A) as the valve is opened
hydraulically and hence the pump Port P is connected to port A as shown in fig b. Inthe
other direction the valve is closed by the ball poppet ( note the fluid pressure from A
pushes the ball to its seat) and hence the flow from the port A is blocked ( fig a.). The
symbol for this type of design is same as that of check valve.(fig4.6c)
No flow

Free flow
Fig 4.6c. Symbol of 2/2 poppet valve ( Check valve )
2. Spoolvalves: The spool valve consists of a spool which is a cylindrical member
that has large- diameter lands machined to slide in a very close- fitting bore of the valve
body. The spool valves are sealed along the clearance between the moving spool and
the housing. The degree of sealing depends on the size of the gap, the viscosity of the
fluid and especially on the level of pressure. Especially at high pressures ( up to 350bar)
leakage occurs to such a extent that it must be taken into account when determining the
system efficiency. The amount of leakage is primarily dependent on the gap between
spool and housing. Hence as the operating pressure increases the gap must be reduced or
the length of overlap increased. The radial clearance is usually less than 20 . The
grooves between the lands provide the flow passage betweenports.
1. Two-way valve ( 2/ 2DCV):
Lever for manual actuation
Bore Port A Valve Body
Spring

Spool

PortP a) Valve closed

 Port A
Spring

PortP b) Valve opened by actuation

Fig 4.7 Spool type 2 / 2DCV
The simplest type of directional control valve is a check valve which is a two way
valve because it contains two ports. These valves are also called as on-off valves because
they allow the fluid flow in only in one direction and the valve is normally closed. Two –
way valves is usually the spool or poppet design with the poppet design more common
and are available as normally opened or normally closed valves. They are usually
actuated by pilot (Hydraulic actuation ) but manual, mechanical , solenoid actuated
design are also available. Figure 4.7 above shows Spool type 2 / 2 DCV manually
actuated. In Fig 4.7 a) the port P is blocked by the action of spring as the valve is
unactuated ( absence of hand force). Hence the flow from port P to A is blocked. When
actuated ( Presence of hand force ) the valve is opened, thereby connecting port P to A.
2. Three – wayvalve: A directional control valve primary function is
alternatively to pressurize and exhaust one working port is called three-way valve.
Generally, these valves are used to operate single- acting cylinders. Three-way
directional valves are available for manual, mechanical, pilot, solenoid actuation.
These valves may be two-position, or three -position. Most commonly they have
only two positions, but in some cases a neutral position may be needed. These valves
are normally closed valves ( i.e the pump port is blocked when the valve is not
operating ). The three-way valve ports are inlet from the pump, working ports , and
exhaust to tank. These ports are generally identified as follows : P= pressure(
Pump)port ; A or B = working port and T = tank port. Figure 4.8 (a) and (b) shows
the two position of the three – way valve actuated manually by a pushbutton.
a. Spool position 1: When the valve is actuated, the spool moves towards left . In
this position flow from pump enters the valve port P and flows out through theport
A as shown by the straight- through line and arrow ( fig a). In this position, port T
is blocked by thespool.
b. Spool position 0: when the valve is un-actuated by the absence of hand force, the
valve assumes this position by the action of spring In this position, port P is blocked
by the spool. Flow from the actuator can go to the tank from A to T as shown by
straight – through line and arrow ( Fig a).
 spool A Push button formanual
actuation

P T ValveBody
Fig a. 1 position: P to A , T blocked
spring PortA

PortP T b) 2 position : Valve closed

Fig 4.8 2 /3DCV
Symbol 2/ 3 DCV : -
0 1
3. Four -wayDCV: - These valvesa re generally used to operate cylinders and
fluid motors in both directions hydraulically. The four ways are Port P that is
connected to pump, tank port T, and two working ports A and B connected to the
actuator. The primary function of a four way valve is to alternately to pressurize and
exhaust two working ports A & B. These valves are available with a choice of
actuation, manual, mechanical, solenoid, pilot & pneumatic. Four-way valve comes
with two or three position. One should note that the graphical symbol of the valve
shows only one tank port even though the physical design may have two as it is only
concerned with the function.
3.1. Three positions, Four way valve: These type of DCV consists of three
switching position. Most three- position valves have a variety of possible flow path
configurations, but has identical flow path configuration in the actuated position (
position 1 and position 2)and different spring centered flow paths. When left end of
the valve is actuated, the valve will assume 1 position. In this position the port P to
connected to working port A and working port B is connected to T (in some design P
is connected to B, and A to T when left end is actuated ). Similarly when the right
end is actuated, the valve will assume 2 position. In this position port P is connected
to B and working port A to T. When the valve is un-actuated, the valve will assume
its center position due to the balancing opposing spring forces. It should be noted
that a three-position valve is used whenever it is necessary to stop or hold a actuator
at some intermediate position within its stroke range, or when multiple circuit or
functions must be accomplished from one hydraulic powersource.
Three- position, four- way DCV have different variety of center
configurations. The common varieties are the open center, closed center, tandem
center, floating center, & regenerative center with open, closed and tandem are the
three basic types A variety of center configurations provides greater flexibility for
circuit design.

a.) Open center 3 / 4 DCV: In open- center circuit, all ports are open to each other
in the center position. When the valve is in open center position, the pump flow is
directed to the tank at atmospheric pressure. At the same time the actuator can be
moved freely by applying an external force. Open center valve help to prevent heat
buildup, and no work can be done by any part of the system, as long as the valve
remains in the center position, since the fluid always follows the path of least
resistance . This means that other auxiliary devices in the system using pressure
energy cannot function.
 Figure 4.9 a,b,c. shows the three positions of 3 / 4 DCV. Fig 4.9a. shows
the valve is mid position i.e when the valve is deactuated. In fig 4.9 b. since the left
end of the valve is actuated , the valve assumes 1 position. Here port P is connected
to A and B is connected to T. In fig 4.9 c, since the right end of the valve is actuated ,
the valve assumes 2 position. Here port P is connected to B and A is connected toT.

PortB A Spool

Bore

T PortP T
a )Mid position : Open Center
Valvebody Port B A

Actuation

T PortP T
b )1 Position, Flow : P to A & B to T

PortB A

Actuation
 T PortP T

c ) 2 position: Flow : P to B & A toT

Fig 4.9 ( a, b, c ): 3 position- 4 way , open centered DCV

(Note : In Fig b & c spring not shown)
A B

P T
0
Fig 4.9d.
1 Symbol : Open2 Center 3 / 4 DCV

b.) Closed Center 3 / 4 DCV:

Port B A Spring

Bore Spool

T PortP
TMid Position:
ClosedCenter
Fig 4. 10a. Closed Center 3 / 4 DCV
A B

1 0 2

P T
Fig 4.10b.Symbol
Figure 4.10 shows a closed center 3- position, 4 – Way DCV in its center position.
The working of the valve is similar to open center DCV and in actuated position the port
connection is identical. In closed center DCV all ports are closed to each other. Hence
the actuator connected to ports A and B is hydraulically locked and cannot be moved by
an external force In this position the pump flow must go over the relief valve when flow
is not being used for any other parts of the circuit. This forces the pump to produce flow
at the high pressure setting of the pressure relief valve. This not only waste pump design
power but promotes wear and shortens pump life. Also the temperature of oil is raised
due to heat buildup in the system. This promotes oil oxidation , viscosity drop, which
further raises the wear of parts and increased leakage. With this type of center in DCV,
when the valve actuates to switching position 1 or 2, two things may happen. If pressure
port ( P to working port A or B) opens first pressure in the system raises which is not
desirable, and if tank port open first pressure drops. Closed –center versions are used only
when multiple circuit or functions must be accomplished in the system from one power
source.
c.) Tandem centered 3 /4 DCV: Figure 4.11 shows a tandem center 3-position, 4-way
DCV. In the center configuration, the working ports A and B are blocked , and the pump
port P is connected to tank port T. The tandem center also results in a locked actuator.
However, it also unloads the pump at atmospheric pressure. The application of this
design may be to hold a cylinder or fluid motor under load or to permit the pump flow to
be connected to a series of valves for multiple circuitry.
PortB A Spool
Bore

T PortP T
Fig 4.11a. Tandem Center 3 / 4 DCV :Mid position
A B

1 0 2

P T
Fig 4.11b. Symbol

d.) Regenerative Center 3 / 4 DCV: This is another type of common center

configuration used in hydraulic circuits. Regenerative means the flow generated from the
system itself. Regenerative center is used whenever the actuator movement in one
direction requires two different speeds eg., Part of length of extending stroke of actuator
requiring fast movement during no load condition and remaining length slow controlled
motion. During fast extending the DCV is un-actuated thereby by spring forces it comes
to the mid position. This center saves on additional pump capacity required.
Fig 4.12 shows double acting single rod cylinder connected to 3 / 4 DCV having
regenerative center. The piston area(A) is more than ring area (B) . When the cylinder is
actuated by this type of DCV , in the center configuration, the pump flow is directed
towards A, since the piston area is more it offers least resistance( fluid flows always in
the path of least resistance ) and hence the fluid flows towards A. The return flow from B
also joins the pump flow, which increased the piston speed due to increased flow

Piston PistonRod

Cylinder A B

A B

1 0 2

P T
Fig 4.12 Double acting cylinder connected
toRegenerative center 3 /4 DCV

Fig 4.13 shows Regenerative center type 3 / 4 DCV in its mid position. In the mid
position Pump Port P is connected to A and B, and tank port T is blocked.
Bore Spool

Port B A Spring
 T PortP
T
MidPosition
Fig 4. 13a. Regenerative Center 3 / 4 DCV
A B

1 0 2
:
P T
Fig 4.13b. Symbol

e.) Floating Center 3 / 4 DCV :

Bore Spool

Port B A Spring

T PortP
T
MidPosition:
Fig 4. 14a. Floating Center 3 / 4DCV
A B

1 0 2

P T
Fig 4.14b. Symbol :

Figure 4.14 shows floating center 3 / 4 DCV in its mid position. In this
position the pump port is blocked and the two working ports A and B are connected
to tank port T. Since the working ports A and B are connected to tank T, the actuator
can be moved freely without any external force and hence the name floating. In this
valve also like in closed center, in the mid position the pump flow must go over the
relief valve when flow is not being used for any other parts of the circuit. This
forces the pump to produce flow at the high pressure setting of the pressurerelief
 valve, which buildsup heat in the circuit. Hence this center configuration is used
only in special case.

3.2 Two- position, Four – way DCV :These valves are also used to operate double
acting cylinder. These valves are also called as impulse valve as 2 / 4 DCV has
only two switching positions, i.e it has no mid position. These valves are used to
reciprocate or hold and actuating cylinder in one position. They are used on
machines where fast reciprocation cycles are needed. Since the valve actuator moves
such a short distance to operate the valve from one position to the other, this design
is used for punching, stamping and for other machines needing fast action. Fig 4.15a
and b shows the two position of 2 / 4DCV.

Bore Spool
PortB A

Actuation

T PortP T
a. 1 Position : P to A and B toT

Bore Spool
PortB A

Actuation

T PortP T
b. 2 Positon, P to B and A to T
Fig 4.15: 2 / 4DCV
 1 2
11

Fig 4.15c.Symbol

Actuation of Directional control valves : Directional control valves can be actuated

by different methods.
1. Manually – actuated Valve: A manually actuated DCV uses muscle power to
actuate the spool. Manual actuators are hand lever , push button, pedals . The
following symbols shows the DCV actuatedmanually

1 2

Fig 4.16.
Fig 4.16 shows the symbol of 2 / 4 DCV with manually operated by roller tappet to
1 and spring return to 2.

1 2

Fig 4.17
Fig 4.17 shows the symbol of 2 / 4 DCV with manually operated by hand lever to 1
and spring return to 2.
In the above two symbols the DCV spool is returned by springs which push the
spool back to its initial position once the operating force has stopped e.g, letting go of
the hand lever
2.Mechanical Actuation: The DCV spool can be actuated mechanically, by roller and
cam, roller and plunger. The spool end contains the roller and the plunger or cam can be
attached to the actuator (cylinder).. When the cylinder reaches a specific position the
DCV is actuated. The roller tappet connected to the spool is pushed in by a cam or
plunger and presses on the spool to shift it either to right or left reversing the direction of
flow to the cylinder. A spring is often used to bring the valve to its center configuration
whendeactuated.
3.Solenoid-actuated DCV: A very common way to actuate a spool valve is by using a
solenoid is illustrated in Fig 4.18. When the electric coil (solenoid) is energized, it
creates a magnetic force that pulls the armature into the coil. This caused the armatureto
push on the spool rod to move the spool of the valve.. The advantage of a solenoid lies
with in its less switchingtime.
 EnergizedCoil Spool
Armature Bore B A

SpoolRod T P T

Fig 4.18 Working of solenoid to shift spool of valve.

Figure 4.18 shows the working of a solenoid actuated valve when left coil is
energized, its creates a magnetic force that pulls the armature into the coil. Since the
armature is connected to spool rod its pushes the spool towards right. Similarly when
right coil is energized spool is moved towards left. When both coil is de-energized the
spool will come to the mid position by spring force Figure 4.16 a shows a symbol for
single solenoid used to actuate 2- position ,4 way valve and b) shows symbol for 2
solenoids actuating a 3- position valve, 4 way valve..

1 2

Fig 4.18 a) Symbol forSingle solenoid-actuated , 2- Position,

4-way spring centered DCV
.
1 0 2

Fig 4.18 b) Symbol for Solenoid actuated, 3- position,

,4- way spring centered DCV
4.Hydraulic actuation: This type actuation is usually known as pilot- actuated valve. The
hydraulic pressure may directly used on the end face of the spool . The pilot ports are
located on the valve ends. Fig 4.19a. shows a directional valve where the rate of shifting
the spool from one side to another can be controlled by a needle valve. Fluid enteringthe
pilot pressure port on the X end flows through the check valve and operates against the
piston. This forces the spool to move towards the opposite position. Fluid in the Y end
(right end ,not shown in the figure) is passed through the adjustable needle valveand
exhausted back to tank. The amount of fluid bled through the needle valve controls how
fast the valve will shift. Fig 4.19b. shows the symbol of pilot actuated 2 / 4 DCV.

Part of Valve Body

Needle valve Port

Spool

Pilot port X
Fig 4.19a. Pilot actuatedDCV
A B

Y
X P T
Fig 4.19b..Symbol for pilot actuated 2 /4 DCV

5. Pneumatic actuation: Directional control valve can also be shifted by applying air
pressure against a piston at either end of the valve spool. When air is introduced
through the left end passage ( X), its pressure pushes against the piston to shift the
spool to the right. Removal of this left end air supply and introduction of air through
the right end passage (Y) causes the spool to shift to the left. Figure 4.19 shows the
symbol for pneumatic actuated 2 / 4 DCV. Note that the shaded arrow represents the
pilot actuation as in fig 4.20 and the unshaded arrow represent pneumatic signal.

A B

X Y
P T
Fig 4.20. Symbol for Pneumatic actuated 2 / 4 DCV
6. Indirect actuation of directional control valve: We have seen that a directional
valve spool can be positioned from one extreme position to another by actuated it by
manually, mechanically, electrically ( solenoid) , hydraulic(pilot) and pneumatic. The
mode of actuation has no influence on the basic operation of these switching circuits.
However since there is usually not a lot of force available, direct actuation is
restricted to use with rather smaller valves. Especially with direct actuation, the
greatest disadvantage is that the force which can be developed by them to shift a
directional valve spool is limited. As a matter of fact, the force required to shift a
directional spool is substantial in the largersize.
Larger valves are often indirectly actuated in one after the other sequence.
First the smaller valve is directly actuated. Flow from the smaller valve is directed to
either side of the larger valve when shifting is required. The main DCV is referred as
pilot actuated DCV. The control oil can come from a separate circuit or from the
same system’s pressure line. Pressure for pilot valve operation is usually supplied
internally from the pressure passage in the main valve. These two valves are often
incorporated as a single unit. Therefore one may find it hard to see that it is an
indirectly controlled valve. These valves are also called as Electro-hydraulic operated
DCV.

Main( larger ) DCV , 3 / 4 closed

Center , pilot actuated
A B
X Y ControlSignal
1 0 2

P T

A B

1 0 2

P T
 Solenoid actuated
P Floating center 3 / 4 DCV
( Smaller valve)
 Fig 4.21a. Symbol for Indirect actuation
For 3 / 4 DCV

A B

1 0 2

P T

Fig 4.21b. Combined symbol:.Solenoid actuated internal pilot

operated,3 / 4 closed center DCV

Valve Lap:Valve lap is essential. It the sealing length that exist between various
pressure ports. It is achieved by the tolerance between the spool and the housing.
Compared to poppet valves, hermetic sealing is not possible. The seal effect is therefore
dependent on the dimension of the sealing aperture and the fluid viscosity. There are two
types of lap.
1. Lap in stationary condition: The leakage rate between various pressure port is
dependenton:
Seal length between port and spool (S ) : If large lap is provided leakage is less,but
it increases the switching time. In servo valves S=0
The spool play or clearance- It is clearance space ( C)between spool and the bore.
Large clearance means more leakage.The diameter of thespool.
The pressure differential.

.
S Ports
Spool
Bore
 Fig 4.22: Seal Length Between port and spool

Ports
Spool

C Bore

Fig 4.23 : Clearance between spool and Bore

Note : C = 20µ
2. Lap during Switching or cross over condition in DCV: Two position directional
control valve can be equipped with a cross over center condition. This center
condition is what an actuator sees for a fraction of a second as the valve shifts from
one extreme to another. That is, it indicates how the port connection are established
during change over of the valve. Open and Closed center conditions are the most
frequently used crossover.
Negative lap during switching ( or under lap ) - Open center crossover:
During changeover from one switching position to another switching position
momentarily all the ports are interconnected with one another. The advantage is there is
no switching impact i.e, no pressure peak .the disadvantage is that the pressure falls
momentarily which may lower the load , the accumulator is emptied etc.,

A B

1 2

P T
Fig 4.24 Open Center cross over
Positive lap during switch over ( over lap) ; Closed center crossover:
During changeover from one switching position to another switching position
momentarily all the ports are blocked. Advantage: The valve does not allow the
system pressure to drop severely during a shift. As the directional valve shifts system
pressure is immediately present to reverse the actuator. The disadvantage is pressure
peaks momentarily in positive type of valve cross over This type can be lpressure
pre- opening and tank pre-opening.
a. Pressure pre- opening: During change over pressure port connection closeslast
and it opens first in next switching position. It is mostly used for control of
hydraulic motors. It provides instantreversing.

A B

P T
Fig 4.25. Pressure pre- opening

b. Tank pre- opening: During change over tank port connection closes last andit
opens first in next switching position. It is used for control of cylinders with
differential areas ( decompressionfacility).

A B

P T
Fig 4.26. Tank pre- opening

In reversing, a high inertial loads, it is preferable to use open center cross

over which allows the actuator lines to bleed slightly before reversal takes place. If a
closed center cross over is used with this type of load, the inertia of the load, would
build up pressure in an actuator line which could be quite high.

----------------------------

PRESSURE CONTROL VALVE

 These are the units ensuring the control of pressure. A throttling orifice is present in
the valve and by variation of orifice, the pressure level can be controlled or at a
particular pressure, a switching action can be influenced.
Classification: Basically one differentiates between pressure regulating and pressure
switching valves. Pressure regulation valves are for maintaining a constant pressure in
a system. Pressure switching valves, apart from a definite control function they also
perform a switching action. Such valves not only provide a switching signal, as in the
case of pressure switches, but also operate themselves as a DCV type of switching
within the hydraulic system. In the case of pressure switching valves the piston or
spool of the valve remains at a definite position either open or closed depending on
the control signal (Yes or No ). The control signal is generally external to thevalve.
In the case of pressure regulating valves the piston or spool takes up in between
position depending on the variable pressure and flow characteristics.
As in DCV these valves can also have the valve element either poppet or spool.. With
poppet the sealing is good. But small movement of poppet allows large flows thereby excessive drop
of pressure than required. This results is impact effect.

The spool type of valves allow very fine control or throttling of flows. But of course,
the sealing is not very good.
Opening and closing pressure difference:
The minimum pressure at which the valve action starts is called as the opening
or cracking pressure. The difference between the cracking pressure (commencement
of flow) and the pressure obtained at maximum flow ( normal flow without change of
spring force ) is referred as the “opening pressure difference”.
Similarly the difference between the pressure corresponding to nominal flow and no
flow during closing of the valve is referred as “closing pressure difference”. This is
larger than the opening due to the flow forces acting in the opening direction as also
the hysterisis in the spring.
Different types of pressure control valves:Pressure control valves are usually
named for their primary function such as relief valve, sequence valve, unloading
valve, pressure reducing valve and counterbalance valve.

1. Pressure Reliefvalve:

One of the most important pressure control is the relief valve. Its primary function
is to limit the system pressure. Relief valve is found in practically all the Hydraulic
system. It is normally a closed valve whose function is to limit the pressure to a
specified maximum value by diverting pump flow back to the tank. There are two
basic design, a) direct operated or inertia type, b) the pilot operated design
( compound relief valve ).

Direct type of relief valve: The direct type of relief valve has two basic working
port connection. One port is connected to pump and the other to the tank. The valve
consists of a spring chamber ( control chamber ) with an adjustable bias spring which
pushes the poppet to its seat, closing the valve. A small opening connecting the tank
is provided in the control chamber to drain the oil that may collected due to leakage,
thereby preventing the failure of valve. System pressure opposes the poppet, which is
held on its seat by an adjustable spring. The adjustable spring is set to limit the
maximum pressure that can be attained within the system. The poppet is held in
position by spring force plus the dead weight of spool. When pressure exceeds this
force, the poppet is forced off its seat and excess fluid in the system is bypassed back
to the reservoir. When system pressure drops to or below established set value, the
valve automatically reseats. Fig 4.27a shows a direct pressure relief valve. Fig 4.27b
shows thesymbol.

Screw
(for pressure setting)

Spring Control
Chamber

Drain
(to remove oil from Poppet

Tank

Pump ( When Pressure here is less than

the valve setting, the valve is closed )
Fig 4.27a. Pressure Relief Valve

Fig 4.27b.Symbol

2. UnloadingValve: A unloading valve is used to permit a pump to operate at

minimum load. The unloading valve is normally closed valve with the spoolclosing
the tank port. It operates on the principle that pump delivery is diverted to the tank,
when sufficient pilot pressure is applied to move the spool against the spring force.
The valve is held open by pilot pressure until the pump delivery is again neededby
the circuit. The pilot fluid applied to move the spool upwards becomes a static
system. In other words, it merely pushes the spool upward and maintains a static
pressure to hold it open. When the pilot pressure is relaxed, the spool is moved down
by the spring, and flow is diverted through the valve into the circuit. The spool type
unloading valve is shown in fig 4.28. The valve consists of a spring chamber ( control
chamber ) with an adjustable bias spring which pushes the spool closing the tank
port. The valve has 2 ports one connecting the pump and other connecting the tank.
The movement of the spool inside the bore opens or closes the ports. Drain is
provided to remove the oil that may collect in control chamber due to leakage,
thereby preventing valvefailure.
Unloading valves also helps to prevent heat buildup in a system, which is
caused by fluid being discharged over the relief valve at its pressure setting. The
unloading valve is used in system having one or more fixed delivery pump to control
the amount of flow at any given time. A well designed hydraulic circuit uses the
correct amount of fluid for each phase of a given cycle of machine operations. When
pressure builds up during the feed phase of the cycle, the pilot pressure opens the
unloading valve, causing the large discharge pump to bypass its flow back to the tank.

Screw
(for pressure setting)

Spring Control
Chamber

Drain
Tank

Pump

Remote
Pilot Pressure Signal
Fig 4.28b Unloading Valve
 Fig 4.28a. Symbol

Problem1. A pressure relief valve has a pressure setting of 69 bars. a) Compute

the hydraulic power loss across this valve if it returns all the flow back to the tank
from a 0.0013m3/s discharge pump. b) If unloading valve is used to unload the pump
and if the pump discharge pressure during unloading equals 1.72 bars, how much
power is being wasted?

Solution :
b) Pressure setting, p= 69 bars = 69*105 N / m2 ;
Discharge, Q = 0.0013m3/ s
Power=?

We know, Hydraulic Power = p * Q watts

Hydraulic power loss = 69 *105*0.0013 =8970 watts Ans

b) Discharge pressure during unloading , p = 1.72 bars

Hydraulic power loss = 1.72*105* 0.0013 =223.6watts Ans

One can see that by using unloading valve to unload the pump flow, the power
loss is very much less compared to that of relief valve.

3. Sequencevalve: A sequence valve’s primary function is to divert flow in a

predetermined sequence. It is a pressure- actuated valve similar in construction to a
relief valve and normally a closed valve. The sequence valve operates on the principle
that when main system pressure overcomes the spring setting, the valve spool moves
up allowing flow from the secondaryport.
A sequence valve may be direct or remote pilot- operated. These valves are used
to control the operational cycle of a machine automatically. Sequence valve may be
directly operated as shown in the fig 4.29b. The valve consists of a spring chamber (
control chamber ) with an adjustable bias spring for setting the pressure. It consists of
2 ports, one main port connecting the main line and other (secondary port) connected
to the secondary circuit. Usually the secondary port is closed by the spool. A small
opening connecting the tank is provided in the control chamber to drain the oil that
may collected due to leakage, thereby preventing the failure of valve. The pressure is
effective on the end of the spool. This pressure will urge the spool against the spring
force and at the preset value of the spring it allows a passage from the primary to the
secondary port. For remote operation it is necessary to close the passage used for
direct operation by plugging and provide a separate pressure source as required for
the operation of the spool in the remote operationmode.
 Fig 4.29a.Symbol

Screw
(for pressure setting)

Spring Control
Chamber
Drain

Secondary Port

Pressure ( Main )
Line Spool

Direct Operation
(Control Signal)

Remote
Pilot operation
(Plugged) Fig 4.29b. Sequencevalve

4. CounterbalanceValve: A Counterbalance valve is used to maintain back

pressure to prevent a load from failing. One can find application in vertical presses,
lift trucks, loaders and other machine tool that must position or hold suspendedloads.
The counterbalance valve shown in the figure 4.30a. The valve consists of a
spring chamber ( control chamber ) with an adjustable bias spring which controls the
movement of spool. It has two ports, one connected to load and the other to the tank
A small opening connecting the tank is provided in the control chamber to drain the
oil that may collected due to leakage, thereby preventing the failure of valve.
Counterbalance valve acts on the principle that fluid is trapped under pressure until
pilot pressure, either direct or remote(only one opened at a time and other blocked ),
has to overcomes the spring force setting in the valve. Fluid is then allowed toescape,
letting the load to descend under control. This valve can be used as a “braking
valve” for decelerating heavy inertiaload.
 A counterbalance valve is normally closed valve and will remain closed until
acted upon by a remote pilot pressure source. Therefore, a much lower spring force is
sufficient to allow the valve to operate at a lesser pilot pressure.

Screw
(for pressure setting)

Spring Control
Chamber
Drain

Load

Tank Spool

Direct Operation

Control signal Line

Remote
Pilot operation
(Plugged)

Fig4.30a Counter Balance Valve

Direct pilot

Remote pilot

Fig 4.30b.Symbol

When a counterbalance valve is used on large vertical presses, it mayimportant

to analyze the source of pilot pressure. Figure 4.31 (a) and (b) illustrate the
comparison between direct and remote pilotsignal

FromPump FromPump
 To
Tank To Tank

200bar +

100kN 100 kN

Fig 4.31aDirectPilot Fig 4.31b. Remotepilot

Let Piston area, AP= 100 cm2 =0.01 m2

Ring area, AR= 50 cm2 =
0.005m2Load , F = 100 kN =
100000N
The pressure to support the load is therefore equal to ,
p = F / AR = 100000 / 0.005 = 20*106 N / m2 = 200 bar

Hence a pressure of 200 bar is needed to support the load. If pilot pressure is
taken directly as shown in fig 4.31a, then the counterbalance valve should open at
about 200 bar or slightly higher because of inertia and friction. Hence the spring
setting is about 200 bar or slightly higher. In other case ( fig 4.31b) if remote pilot
pressure is taken from the pressure line at the top of the cylinder, a choice of the
operating pressure can be made for the valve. Since the valve is normally closed
valve and will remain closed until acted upon by a remote pilot pressure source.
Therefore, a much lower spring force can be selected to allow the valve to operate at
a lesser pilot pressure.

5. PressureReducingValve: Pressure reducing valve is used to limit its outlet

pressure. Reducing valves are used for the operation of branch circuits, where
pressure may vary from the main systempressures.
The pressure reducing valve is normally an open type valve. Figure 4.32 shows
the pressure reducing valve. The valve consists of a spring chamber ( control
chamber ) with an adjustable spring to set the pressure as required by the system. A
small opening is provided in the control chamber to drain the oil that may be
collected due to leakage, thereby preventing the failure of valve. A free flow passage
is provided through the valve from inlet to secondary outlet until a signal from the
outlet side tends to throttle the passage through the valve. The valve operates on the
principle that pilot pressure from the controlled pressure side opposes an adjustable
bias spring normally holding the valve open. When the two forces are equal, the
pressure downstream is controlled at the pressure setting. Thus, it can be visualized
that if the spring has greater force, the valves open wider and if the controlled
pressure has greater force, the valves moves towards the spring and throttles the
flow.
 Screw
(for pressure setting)

Spring Control Chamber

Drain

Pump Or Spool
Main Pressure
Side
Out
(Controlled Pressure )
Control Signal Line

Fig 4.32a Pressure Reducing Valve

Fig 4.32b. Symbol

 HYDRAULIC CIRCUIT DESIGN ANDANALYSIS

A Hydraulic circuit is a group of components such as pumps, actuators, and

control valves so arranged that they will perform a useful task. When analyzing or
designing a hydraulic circuit, the following three important considerations must be taken
into account:
1. Safety ofoperation
2. Performance of desiredfunction
3. Efficiency ofoperation

It is very important for the fluid power ( Hydraulics and Pneumatics ) designer to
have a working knowledge of components and how they operate in a circuit.
Hydraulic circuits are developed through the use of graphical symbols for all
components. The symbols have to conform to the ANSI specification.

5.1 Control of a Single- Acting Hydraulic Cylinder:

A single-acting cylinder can exert a force in only the extending direction

as fluid from the pump enters the blank end of the cylinder ( usually left side of the
piston). Single- acting cylinder do not retract hydraulically. Retraction is accomplished
by using gravity or by the inclusion of a compression spring in the rod end.

Fig 5.1Symbol

Force during extension strokeis, Fext= p *AP

Velocity during extension stroke is ,vPext = QP / AP
The force and velocity during retraction stroke depends upon spring rate as
single – acting cylinder do not retract hydraulically
Figure 5.2 shows a two- postion, three way, manually operated, spring offset
directional control valve ( DCV ) used to control the operation of a single – acting
cylinder. In the spring offset mode, full pump flow goes the tank via the pressure relief
valve. The spring in the rod end of the cylinder retracts the piston as oil from the blank
end ‘A’ drains back to the rank. When the valve is manually actuated the pump flow
goes to the cylinder blank end ‘A’ via DCV 1 position. This extends the cylinder. At full
extension, pump flow goes through the relief valve. Deactivation of the DCV allows the
cylinder to retract as the DCV shift into its spring – offset mode.

A
1 0

D P T

E
P R
T

F T

Fig 5.2. Control of Single -Acting Hydraulic Cylinder.

C = Single acting cylinder
P = Pump
E = Electric Motor
T = Tank
F = Filter
R = Relief Valve
D =2-position, 3 way DCV Manually operated and spring
return
5.2 Control of Double -Acting Hydraulic Cylinder:
Double –Acting cylinders can be extended and retracted hydraulically. Thus, an
output force can be applied in two directions.

A B
 Fig 5.3 Double acting cylinder

The output force ( F ) and piston velocity of double acting cylinder are not the
same for extension and retraction strokes. During the extension stroke, fluid enters the
blank end ( A ) of the cylinder through the entire circular area of the piston ( AP ).
However during the retraction stroke, fluid enters the rod end through the smaller
annular area between the rod and cylinder bore ( AP– AR), whereAP= piston area , and
AR= rod area. Since AP= is grreater than ( AP– AR), the retraction velocity is greater than
the extension velocity since the pump flow rate isconstant.

Similarly during the extension stroke, fluid pressure bears on the entire area of
the piston( AP ). However during the retraction stroke, fluid pressure bears on the smaller
annular area ( AP – AR ). The difference in area accounts for the difference in output
force, with the output force is greater during extension.

Extending stroke :
Force, Fext= p*AP ------------- 1
Velocity, vext=Qp/ AP-------- 2

Retraction Stroke :
Force, Fret= p *( AP–Ar) -----------3
Velocity, vret = Qp/ (AP–Ar)----------4

It can be seen from the above 4 equations that force during extension
stroke and velocity of piston during retraction stroke is greater for the same operating
pressure and flowrate.
The power developed by a hydraulic cylinder for either the extension or retraction
stroke, can be found out by (velocity multiplied by force) or from ( flow rate multiplied
by operating pressure)

Power ( kW ) = vp( m / s ) * F ( kN ) = Q ( m3 / s) * p (kPa )

Figure 5.4 shows a circuit used to control a double – acting hydraulic cylinder.
When the four way valve is in centered configuration , the cylinder is hydraulically
locked as the ports A and B is blocked. The pump flow is unloaded back to the tank at
essentially atmospheric pressure.
When the four way valve is actuated into the 1stposition , the cylinder is extended
against its load force Fload as oil flows to the blank end of the cylinder from port P
through port A . Also, oil in the rod end of the cylinder is free to flow back to the tank via
the four way valve from port B through port T. Note that the cylinder would not extend
if this oil were not allowed to leave the rod end of thecylinder.
When the four way valve is actuated into the 2st position , the cylinder is retracts
against as oil flows to the rod end of the cylinder from port P through port B. Oil in the
blank end of the cylinder is returned to the tank from port A to port T.
 At the end of the stroke, there is no system demand for oil. Thus, the pump flow goes
through the relief valve at its pressure- level setting unless the four- way valve is
deactivated. In any event the system is protected from any cylinder overloads.

FLOAD
C

A B

1 0 2

D P T

E P R
T
F
T

Fig 5.4. Control of Double -acting hydraulic cylinder.

C = Double acting cylinder
P = Pump
E = Electric Motor
T = Tank
F = Filter
R = Relief Valve
D =3-position, 4 way ,Tandem center, Manually operated and
Spring CenteredDCV

Problem 1. A double acting cylinder is hooked up to reciprocate. The relief valve setting
is 70 bars. The piston area is 0.016 m2 and the rod area is 0.0045 m2. If the pump flow is
0.0013m3 / s, find the cylinder speed and load- carrying capacity for the
a. Extendingstroke
b. Retractingstroke.
Solution:
Relief valve pressure setting, p = 70 bars = 70 * 105 N /m2
Piston area, Ap = 0.016 m2
Rod area, Ar = 0.0045 m2
Pump flow, Qp = 0.0013 m3/s
a) ExtendingStroke:
Cylinder speed, vpext= Qp / AP
= 0.0013 / 0.016
= 0.0813 m / s

Load carrying capacity, Fload= p * AP

= 70 * 105* 0.016
= 112000 N = 112kN

b) RetractingStroke:
Cylinder Speed, vpRet = Qp / (AP – Ar)
= 0.0013 / ( 0.016 - 0.0045 )
= 0.113 m / s

Load carrying capacity, Fload= p *( AP – Ar )

= 70 * 105*( 0.016 - 0.0045
= 80500 N = 80.5kN

5.3 Regenerativecircuit:

Operation
Figure 5.5 shows a regenerative circuit that is used to speed up the extending
speed of a double-acting hydraulic cylinder. Here the pipelines to both ends of the
hydraulic cylinder are connected to pump, one end (A) through the 2 / 3 way DCV and
the other end (B) directly. The operation of the cylinder during the retraction stroke is the
same as that of a regular double-acting cylinder. Fluid flows through the DCV zero
position from the actuator A side during retraction. In this position, fluid from the pump
directly enters the rod end of the cylinder ( direct connection). Fluid in the blank end
drains back to the tank through the DCV as the cylinderretracts.
When the DCV is shifted to 1 position due to manual actuation, the cylinder
extends. The speed of extension is greater than that for a regular double-acting cylinder
because flow from the rod end (QR) regenerates with the pump flow (Q P) to provide a
total flow rate (QT), which is greater than the pump flow rate to the A side of the
cylinder. ( Area of blank end is more than rod end, thereby blank end provide least
resistance)
 C
A B

1 0

D P T

E P

F
T

Fig 5.5. Regenerative circuit.

C = Double acting cylinder
P = Pump
E = Electric Motor
T = Tank
F = Filter
R = Relief Valve
D =2-position, 3 way , Manually operated and
Spring returnDCV
Cylinder Extending Speed
The total flow rate entering the blank end (A) of the cylinder equals the pump
flow rate plus the regenerative flow rate coming from the rod end of thecylinder:
QT = QP + QR
Or QP= QT- QR---(1)
We know that the total flow rate equals the piston area multiplied by the
extending speed of the piston (Vpext). Similarly, the regenerative flow rate equalsthe
difference of the piston and rod areas (Ap - Ar) multiplied by the extending speed of the
piston. Substituting these two relationships into the eq (1) yields
QP = ApVpext – (Ap – Ar)Vpext
Therefore, QP=ArVp ext
Qp
Hence the extending speed of the piston, V pext = --- (2)
Ar

Thus the extending speed equals the pump flow divided by the rod area. Thus, a
small rod area (which produces a large regenerative flow) provides a large extending
speed. In fact the extending speed can be greater than the retracting speed if the rod area
is made small enough.
Ratio of Extending and Retracting Speeds
Let’s determine under what condition the extending and retracting speeds are equal.
We know that the retracting speed (Vpret) equals the pump flow divided by the difference
of the piston and rod areas:
Qp
Vpret ---(3)
A A
p r

Vpext Qp/ Ap Ar
Dividing eq(1) with (4) we have
Vpret ArQp/(Ap Ar Ar
)

Simplifying we obtain the ratio of extension speed and

retracting speed
Vpext Ap
1 --(4)
Vpret
Ar
We see that when the piston area equals two times the rod area, the extension and
retraction speeds are equal. In general, the greater the ratio of piston area to rod area, the
greater the ratio of extending speed to retracting speed.
Load-Carrying Capacity during Extension :
It should be noted that the load-carrying capacity of a regenerative cylinder during
extension is less than that obtained from a regular double-acting cylinder. The load-
carrying capacity (Fload) for a regenerative cylinder equals the pressure multiplied by
piston rod area rather than the pressure multiplied by piston area. This is due to the same
system pressure acting on both sides of the piston during the extending stroke of the
regenerative cylinder..
Thus Fload=PAr
 Thus, the power obtained from the regenerative cylinder is less because the
extending speed is increased at the expense of load-carrying capacity.
5.4 Regenerative center in DrillingMachine:

C FLOAD

A B
C – Double acting cylinder
D – 3 Position, 4 Way,
1 0 2 Regenerative center,
D P T solenoidactuated,
spring centered DCV
R – Relief Valve
E R F -Filter
P E – Electric Motor
F T T- Tank
P - Pump
T

Fig 5.6 Application in Drilling Machine

Figure 5.6 shows an application of regenerative circuit in a drilling machine. Here a

3-position, 4-way , regenerative center directional control valve is used.
When the DCV is in the spring-centered position, port P is connected to A and Band
tank port T is blocked. In this position pump flow goes to A and flow from rod end of
the cylinder also joins the pump flow to gives rapid spindle advance ( no work is done
during this period)
Why does the spring-centered position give rapid extension of the cylinder (drill
spindle)? The reason is simple. Oil from the rod end regenerates with the pump flow
going to the blank end. This effectively increases pump flow to the blank end of the
cylinder during the spring-centered mode of operation. Once again we have a
regenerative cylinder. It should be noted that the cylinder used in a regenerative circuit is
actually a regular double-acting cylinder. What makes it a regenerative cylinder is the
way it is hooked up in the circuit. The blank and rod ends are connected in parallel
during the extending stroke of a regenerativecenter.
 When the DCV shifts to 1st position, P is connected to A and B to T gives slow feed
(extension) when the drill starts to cut into the work piece. Similarly when the DCV
shifts to 2nd position, P is connected to B and A is connected to T, since the ring area is
less the cylinder will have fast return motion.

Problem 2. A double acting cylinder is hooked up in the regenerative circuit. The relief
valve setting is 70 bars. The piston area is 0.016 m2 and the rod area is 0.0045 m2. If the
pump flow is 0.0013m3 / s, find the cylinder speed and load- carrying capacity for the
a. Extendingstroke
b. Retracting stroke.
Solution:
Relief valve pressure setting, p = 70 bars = 70 * 105 N /m2
Piston area, Ap = 0.016 m2
Rod area, Ar = 0.0045 m2
Pump flow, Qp = 0.0013 m3/s
c) ExtendingStroke:
Cylinder speed, vpext= Qp / Ar
(RegenerativeSpeed) = 0.0013 /0.0045
= 0.29 m / s

Load carrying capacity, Fload= p *Ar

= 70 * 105* 0.0045
= 31500 N = 31.5kN
d) RetractingStroke:
Cylinder Speed, vpRet = Qp / (AP – Ar)
= 0.0013 / ( 0.016 - 0.0045 )
= 0.113 m / s

Load carrying capacity, Fload= p *( AP – Ar )

= 70 * 105*( 0.016 - 0.0045
= 80500 N = 80.5kN

3. A double acting cylinder is hooked up in the regenerative circuit. The relief valve
setting is 100 bars and the pump flow is 0.0016m3 / s. If the regenerative and retracting
speed are equal to 0.25m/ s, find the piston and rod area and also load- carrying capacity
for the
a. Extendingstroke
b. Retractingstroke
Solution:
Relief valve pressure setting, p = 105 bars = 105 * 105 N /m2
Pump flow, Qp = 0.0016 m3/s, Speed = 0.25 m/ s
 We have regenerative cylinder speed, vpext= Qp / Ar
ThereforeRod area, = Qp/ vpext
Ar
= 0.0016 / 0.25
= 0.0064m2
Piston Area, AP= 2 Ar= 2* 0.0064 = 0.0128m2

a) ExtendingStroke:
Load carrying capacity, Fload= p *Ar
= 105 * 105*0.0064
= 67200 N =67.2kN

b) RetractingStroke:

Load carrying capacity, Fload= p *( AP – Ar )

= 105 * 105*( 0.0128 - 0.0065 )
= 67200 N = 67.2kN

5.5 Pump – unloading circuit:

FLOAD
C

A B

1 0 2

P T
D
CV

P
U
F T
T
 Fig 5.7. Pump unloading circuit.
C = Double acting cylinder
 P = Pump
T = Tank
F = Filter
U = unloadingValve
D =3-position, 4 way ,closed center, Manually operated and
Spring CenteredDCV

In Fig. 5.7 we see a circuit using an unloading valve to unload a pump. The unloading
valve opens when the cylinder reaches the end of its extension stroke because the check
valve keeps high-pressure oil in the pilot line of the unloading valve. When the DCV is
shifted to retract the cylinder, the motion of the piston reduces the pressure in the pilot
line of the unloading valve. This resets the unloading valve until the cylinder is fully
retracted, at which point the unloading valve unloads the pump. Thus, the unloading
valve unloads the pump at the ends of the extending and retraction strokes as well as in
the spring-centered position of the DCV.

5.6 Double Pump Hydraulic system ( Hi – Lo circuit)

C FLOAD

A B
0
1 2

D P T

CV

R P1 P2 U
T T
F F

Fig 5.8 Double pump Hydraulic system

P1-- Low discharge, Highpressurepump CV – Checkvalve
P2-- High discharge, Lowpressurepump D – 3 Position, 4 Way,closed
R --Reliefvalve center, manual actuated DCV
U –Unloading valve C- Double actingcylinder
T- Tank F -Filter

Figure 5-8 shows a circuit that uses two pumps, one high-pressure, low-flow pump
and the other low-pressure, high-flow pump. One can find application in a punch press
in which the hydraulic ram must extend rapidly over a large distance with very low
pressure but high flow requirements. However, during the short motion portion when the
punching operation occurs, the pressure requirements are high due to the punching load.
Since the cylinder travel is small during the punching operation, the flow-rate
requirements are alsolow.
The circuit shown eliminates the necessity of having a very expensive high-
pressure, high-flow pump. When the punching operation begins, the increased pressure
opens the unloading valve to unload the low-pressure pump. The purpose of the relief
valve is to protect the high-pressure pump from overpressure at the end of the cylinder
stroke. The check valve protects the low-pressure pump from high pressure, which
occurs during the punching operation, at the ends of the cylinder stroke, and when the
DCV is in its spring-centered mode.

5.7 Counter Balance Valve Application:

CB

CV
F LOAD
A B

1 0 2

D P T

P R
 T
F
T

Fig 5.9. Counter balance application

C = Double acting cylinder mounted vertically
P = Pump
CB = Counter Balance Valve
CV = Check Valve
T = Tank
F = Filter
R = Relief Valve
D =3-position, 4 way , Tandem center, Manually operated and
Spring returnDCV

Figure 5.9 illustrates the use of a counterbalance or back-pressure valve to keep a

vertically mounted cylinder in the upward position while the pump is idling i.e when the
DCV is in its center position. During the downward movement of the cylinder the
counterbalance valve is set to open at slightly above the pressure required to hold the
piston up ( check valve does not permit flow in this direction ). The control signal for the
counterbalance valve can be obtained from the blank end or rod end of the cylinder. If
derived from the rod end, the pressure setting of the counter balance valve equals FL/
(AP-Ar ). If derived from blank end the pressure setting equals FL / AP. This pressure is
less and hence usually it has to be derived from blank end. This permits the cylinder to
be forced downward when pressure is applied on the top. The check valve is used to lift
the cylinder up as the counterbalance valve is closed in this direction. The Tandem -
center directional control valve unloads the pump. The DCV is a manually -actuated,
spring-centered valve with tandem-center flow path configuration.

5.8 Hydraulic Cylinder Sequencingcircuit:

A sequence valve causes operations in a hydraulic circuit sequentially. Figure 5.10 is
an example where two sequence valves are used to control the sequence of operations of
two double-acting cylinders C1 and C2 . When the DCV is shifted into its 1st position, the
left cylinder extends completely, and only when the left cylinder pressure reaches the
pressure setting of sequence valve, the valve opens and then the right cylinder extends. If
the DCV is then shifted into its 2nd position, the right cylinder retracts fully, and then the
left cylinder retracts. Hence this sequence of cylinder operation is controlled by the
sequence valves. The spring centered position of the DCV locks both cylinders in place.
 One can find the application of this circuit in press circuit. For example, the left
cylinder the clamping cylinder C1 could extend and clamp a workpiece. Then the right
cylinder C2, the punching cylinder extends to punch a hole in the workpiece. The right
cylinder then retracts the punch , and then the left cylinder retracts to declamp the
workpiece for removal. Obviously these machining operations must occur in the proper
sequence as established by the sequence valves in the circuit.

C1 C2

CV

SV

SV

D
T

P R

Fig 5.10. Cylinder Sequencing circuit

Operation sequence is : C1 + C2+ C2- C1 -
+ is Extension of piston
- is Retraction of piston
C1& C2 = Double acting cylinder
P = Pump ; SV = Sequence Valve ;
R = Relief Valve
CV = Check Valve ;
T = Tank ; F = Filter
 D =3-position, 4 way , Tandem center, Solenoid operated and
Spring returnDCV

Figure5.11 Automatic Cylinder Reciprocating System:

CV CV

SV SV

D
T

P R

T
Fig 5.11. Automatic Cylinder Reciprocating System using Sequence valves
C = Double acting cylinder
P = Pump
 SV = Sequence Valve
CV = Check Valve ; R = Relief Valve
T = Tank ; F = Filter
D =2-position, 4 way , pilot operated DCV
Figure 5.11 shows a circuit that produces continuous automatic reciprocation of a
hydraulic cylinder. This is accomplished by using two sequence valves, each of which
senses a stroke completion by the corresponding buildup of pressure. Each check valve
and corresponding pilot line prevents shifting of the four-way valve until the particular
stroke of the cylinder has been completed. The check valves are needed to allow pilot oil
to leave either end of the DCV while pilot pressure is applied to the opposite end. This
permits the spool of the DCV to shift as required.
An alternative circuit diagram is shown in Figure 5.12 . In the circuit as the cylinder
reciprocates, the pilot directional valve is operated by solenoid DCV to supply fluid to
either end of the main four way directional valve. This causes the machine to reciprocate
automatically, and it will not stop until pump is shut off.

Limit Switch

1 2
C 1

A B D2

1 2

D1 P T

P R
T
F
T

Fig 5.12. Automatic Cylinder Reciprocating System using DCV’s.

C = Double acting cylinder
P = Pump
 R = Relief Valve
T = Tank ; F = Filter
D1 =2-position, 4 way , pilot operated DCV
D2 =2-position, 4 way , mechanical operated DCV
The limit switch 1 and 2 will alternatively energize and deenergize solenoid
,thereby changing the directional of fluid flow into the pilot

5.10. Locked cylinder using pilot check valves:

FLOAD
C

PCV1 PCV2

A B

1 0 2

D P T

P R
T
F
T

Fig 5.13. Locked Cylinder using Pilot Check Valve.

C = Double acting cylinder
P = Pump
 PCV1& PCV2 = Pilot Check Valve
R = Relief Valve
T = Tank ; F = Filter
D =3-position, 4 way , closed center, manually operated DCV
In many cylinder applications, it is necessary to lock the cylinder so that its piston
cannot be moved due to an external force acting on the piston rod. One method for
locking a cylinder in this fashion is by using pilot check valves, as shown in Fig 5.13.
The cylinder can be extended and retracted as normally done by the action of the
directional control valve. If regular check valves were used, the cylinder could not be
extended or retracted by the action of the DCV. An external force, acting on the piston
rod, will not move the piston in either direction because reverse flow through either pilot
check valve is not permitted under these conditions.

5.12. CYLINDER SYNCHRONIZING CIRCUITS :

a. Cylinder connected in series: Figure 5.14 is a very interesting circuit, which seems to
show to show how two identical cylinders can be synchronized by piping them in
parallel. However, even if the two cylinders are identical, it would be necessary for the
loads on the cylinders to be identical in order for them to extend in exact synchronization.
If the loads are not exactly identical (as is always the case), the cylinder with the smaller
load would extend first because it would move at a lower pressure level. After this
cylinder has fully completed its stroke, the system pressure will increase to the higher
level required to extend the cylinder with the greater load. It should be pointed out thatno
two cylinders are really identical. For example, differences in packing friction will vary
from cylinder to cylinder. This alone would prevent cylinder synchronization for the
circuit of Fig.5.14.
C1&C2= Double acting cylinder P
=Pump
T = Tank
F =Filter
R = Relief Valve
D =3-position, 4 way , Tandem center, Solenoid operated and
Spring returnDCV
 C1 FLoad

C2
FLoad

A B

1 0 2

D P T

E P R
T
F
T

Fig 5.14. Cylinder hooked in parallel for

synchronizing(will not operate)

b. Cylinders connected in Series:

The circuit of Fig. 5.15 shows a simple way to synchronize two cylinders. Fluid from the
pump is delivered to the blank end of cylinder 1, and fluid from the rod end of cylinder 1
is delivered to the blank end of cylinder 2. Fluid returns to the tank from the rod end of
cylinder 2 via the DCV. Thus, the cylinders are hooked in series. For the two cylinders to
be synchronized, the piston area of cylinder 2 must equal the difference between the areas
of the piston and rod for cylinder 1. It should also be noted that the pump must be capable
of delivering a pressure equal to that required for the piston of cylinder 1 by itself to
overcome the loads acting on both cylinders. It should be noted that the pressure at the
blank end of cylinder 1 and the rod end of cylinder 2 are equal as per Pascal’s law.

P1Ap1 - P2(Ap1 – Ar1) = F1

And

P2Ap2 - P3(Ap2-Ar2) = F2

Adding both equations and noting that AP2 = Ap1 – AR1 and that P3 = 0 (due to the drain
line to the tank), we obtain the desired result
P1Ap1= F1 + F2

P1
P2
C1 FLoad

P3
P2
C2
FLoad

A B

1 0 2

D P T

P R
 T
F
T
Fig 5.15. Cylinder hooked in Series for
synchronizing( Will Operate )
C1&C2= Double acting cylinder hooked in series P
=Pump
T = Tank
F =Filter
R = Relief Valve
D =3-position, 4 way , Tandem center, Solenoid operated and
Spring returnDCV
 HYDRAULIC CIRCUIT DESIGN AND ANALYSIS-2

5.13 Speed control ofHydraulicCylinder: Speed control of a hydraulic cylinder is

accomplished using a flow control valve. A flow control valve regulate the speed of the
cylinder by controlling the flow rate to and of theactuator.
There are 3 types of speed control:
Meter- in circuit ( Primary control)
Meter-out circuit ( Secondary control)
Bleed - off circuit ( By pass control)

1. Meter – in Circuit: In this type of speed control, the flow control valve isplaced
between the pump and the actuator. Thereby, it controls the amount of fluid going into
the actuator. Fig 5.16 shows meter-incircuit.

FLOAD
C

CV FCV

1 0 2
D

F R

Fig 5.16. Meter – in circuit.

C = Double acting cylinder ; P = Pump ; T = Tank ; F = Filter
 R = Relief Valve; CV = Check Valve ; FCV = Flow control Valve
D =3-position, 4 way ,Tandem center, Manually operated ,Spring Centered DCV
 When the directional control valve is actuated to the 1st position, oil flows through
the flow control valve to extend the cylinder. The extending speed of the cylinder
depends on the setting (percent of full opening position) of the flow control valve.
When the directional control valve is actuated to the 2nd position, the cylinder retracts as
oil flows from the cylinder to the oil tank through the check valve as well as the flow
control valve.
Analysis of Extending Speed Control :
During the extension stroke, if the flow control valve is fully open, all the flow from the
pump goes to the cylinder to produce maximum cylinder speed. As the flow control valve
is partially closed its pressure drop increases. This causes an increase in pressure p1.
Continued closing of the flow control valve ultimately results in pressure p1 reaching and
exceeding the cracking pressure of the pressure relief valve (PRV). The result is a slower
cylinder speed since part of the pump flow goes back to the oil tank through the PRV
setting and the amount of pump flow that is not desired by the cylinder flows through the
PRV. An analysis to determine the extending speed is given as follows:
The flow rate to the cylinder equals pump flow rate minus the flow rate through the PRV.
Qcyl= Qpump – QPRV
The flow rate through the flow control valve (FCV) is governed by
QFCV = CV P / Sg = CV (p1 – p2 ) / Sg
Where P = pressure drop acrossFCV
CV = capacity coefficient of FCV
Sg = specific gravity of oil
Pressure p1 = pPRV = Relief valve pressure setting
Also, pressure p3 = 0 (ignoring small frictional pressure drop in drain line from rod
end of cylinder to oil tank).
Pressure p2can be obtained by summing forces on the hydraulic cylinder.
p2Apiston= Fload or p2 =Fload/Apiston ---(a)
Finally the extending speed of the cylinder is found.
Vcyl= Qcyl/ Apiston =QFCV/Apiston --------------- (b)

usingEqs. (a) and (b) yields the final result.

Cv PPRV −Fload / Apiston

Vcyl ------ ( 1)
Apiston Sg
 As can be seen by Eq. 1, by varying the setting of the flow control system, and thus
the value of CV, the desired extending speed of the cylinder can be achieved.
2. Meter – out Circuit: In this type of speed control, the flow control valve is placed
between the actuator and the tank . Thereby, it controls the amount of fluid going out of
the actuator. Fig 5.17 shows a meter-outcircuit.

FLOAD
C

1 0 2

Fig 5.17. Meter – out Circuit.

C = Double acting cylinder; P = Pump ; T = Tank; F = Filter

R = Relief Valve; CV = Check Valve ; FCV = Flow control Valve
D =3-position, 4 way ,Tandem center, Manually operated and
Spring CenteredDCV
 Meter-in systems are used primarily when the external load opposes the
direction of motion of the hydraulic cylinder. An example of the opposite situation is the
case of a weight pulling downward on the piston rod of a vertical cylinder. In this case
the weight would suddenly drop by pulling the piston rod down if a meter-in system is
used even if the flow control valve is completely closed. Thus, the meter-out system is
generally preferred over the meter-in type. One drawback of a meter-out system is the
possibility of excessive pressure buildup in the rod end of the cylinder while it is
extending. This is due to the magnitude of back pressure that the flow control valve can
create depending on its nearness to being fully closed as well as the size of the external
load and the piston-to-rod area ratio of the cylinder. In addition an excessive pressure
buildup in the rod end of the cylinder results in a large pressure drop across the flow
control valve. This produce the undesirable effect of a high heat generation rate with a
resulting increase in oil temperature.

3. Bleed – off Circuit: In this type of speed control, the flow control valve is placed
between the pressure line and return line . Thereby, it controls the fluid by bleeding off
the excess not needed by the working cylinder. Fig 5.18 shows the bleed-offcircuit.

FLOAD
C

1 0 2

Fig 5.18. Bleed – 0ff Circuit.

C = Double acting cylinder; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
 D =3-position, 4 way ,Tandem center, Manually operated , Spring Centered DCV
This type of flow control is much more efficient than the inlet restricting type for
meter-in, because the bypass feature allows fluid to be exhausted to the tank at just
slightly higher pressure than that necessary to do the work. With the meter-in type, pump
delivery not used would discharge over the main relief valve at maximum pressure.

Problem 1 : An actuator forward speed is controlled by a meter-in circuit. The pressure setting of relief
valve is 50 bar and the pump discharge = 30 litres /min. The cylinder has to carry a load of 3600 N during
theforwardmotion.Theareaofpistonis15cm2androdarea=8cm2.Theflowcontrolvalveissettoallow only 10
litres/ min. Calculate the power input to motor, forward speed and return speed and efficiency of thecircuit.

Solution:
p2 = Fload / AP = 3600 / 0.0015
= 2400000N/m2= 24 bar.
P = 50-24 = 26 bar
Power input to the motor = p 1 *QP/ m
=50 *105*0.0005/0.85
=2941watts=2.94 kW Ans
Forward speed, v F= QFCV/AP
=0.00016 / 0.0015
= 0.16m/s Ans

Return speed , v r= QP/ (AP-Ar)

= 0.0005 / ( 0.0015 -0 .0008)
=0.71m/s Ans

= output / input= p2 QFCV/ p1 QP

5
= 24*10 *0.00016
50*105* 0.0005
= 0.1536 = 15.36% Ans

5.14 Speed control of Hydraulic Motor: Figure 5.19 shows a circuit where speed
control of a hydraulic motor ( Bi -directional motor) is accomplished using a flow
control valve to control the fluid flow to themotor.
 In the spring-centered position of the tandem four-way valve, the motor is
hydraulically locked. When the four-way valve is actuated into the 1st position, the motor
rotates in one direction. Its speed can be varied by adjusting the setting of the throttle of
the flow control valve. In this way the speed can be infinitely varied as the excess oil
goes to the tank through the pressure relief valve. When the four-way valve is
deactivated, the motor stops suddenly and becomes locked. When the 2nd position of the
four-way valve is in operation, the motor turns in the opposite direction. The pressure
relief valve provides overload protection if, for example, the motor experiences an
excessive torque load.

1 0 2
D

F R

Fig 5.19. Speed control of Hydraulic motor using Flow control valve.
M = Bi-directional Hydraulic motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
D =3-position, 4 way ,Tandem center, Manually operated and Spring Centered DCV

The speed of hydraulic motor can be controlled either by meter-in control or

meter- out control.
 Figure 5.20 shows a unidirectional hydraulic motor speed is controlled by a meter- in
circuit. Here the flow control valve is placed between the pump and motor.
 FCV Q1

P M
R QL
(
Q1-QL)
F

Fig 5.20. Meter- in Speed control of Hydraulic motor

M = Uni-directional Hydraulic Motor ; P = Pump ; T = Tank; F = Filter

R = Relief Valve; FCV = Flow control Valve

Figure 5.21 shows a unidirectional hydraulic motor speed is controlled by a meter- out
circuit. Here the flow control valve is placed between the motor and tank.
Q1

P M
QL

FCV
R
F
( Q1 - QL)
Fig 5.20. Meter- out Speed control of Hydraulic motor
M = Uni-directional Hydraulic Motor ; P = Pump ; T = Tank; F = Filter
R = Relief Valve; FCV = Flow control Valve
 We know that the volumetric efficiency of the motor is given by
Vol = Theoretical flow rate the motor should consume
Actual flow rate consumed by motor

Vol = Q T /Q A
Due to leakage, a hydraulic motor consumes more flow rate than it should
theoretically consume. The theoretical flow rate is the flow rate a hydraulic motor would
consume if there were no leakage. If Q1(=QA ) is the flow of fluid to the motor, and QL
the leakage , Then QT is equal to Q1 – QL

Then Vol = (Q1 – QL )/ Q1

In meter- in control Q1 is maintained constant despite varying load , QL varies with
load , therefore volumetric efficiency varies with load. Hence meter-in system will not
give precise control of speed. Whereas in meter – out control Q1 varies with load hence
precise control of speed regardless of flow.

5.15 Hydrostatic Transmission( HST ): These are special cases of energy

transmission system. It consists of a drive with hydraulic energy as input. Hydraulic
motor convert hydraulic energy to mechanical energy. Hydrostatic transmission is a
whole unit in which pumps and motors are designed to match ( the speed torque
characteristics ) to get optimum transmission. The HST can be open or closedcircuit.
(fig 5.21)

PUMP
P. E
M .E MOTOR M.E

Fig 5.21 Hydrostatic transmission

Open circuitHST: Figure 5.22 shows open type circuit. They are called open circuit
drives because the pump draws its fluid from a tank. Its output is then directed to a
hydraulic motor and discharged from the motor back to the tank. In the closed circuit
drive, exhaust oil from the motor is returned directly to the pumpinlet.

Variable displacement pump

M

R
 Fig 5.22 Open circuit (open loop ) HST

Figure 5.23 shows a closed circuit that allows either direction of motor rotation.
The feed pump is provided for replenishing the fluid in the circuit. The check valves
prevent the oil flow from the main pump to the feed pump. Here two relief valve R 1 and
R2are used to protect the main pump in both the direction ofrotation.
The motor speed is varied by changing the pump displacement. The torque
capacity of the motor can be adjusted by the pressure setting of the relief valve.
Closed circuit drives are available as completely integrated units with all the
controls and valving enclosed in a single, compact housing.

Variable displacement
Pump ( Main )

R1 R2

Pump
Feed

Fig 5.23 Closed circuit (open loop ) HST

Performance:
1. Hydraulic power input , Phyd= p QP( Watts )
where p = pressure setting of relief valve in N /m2
QP = pump theoretical flow rate = pump displacement (m3/ rev) * Speed (rps)
2. Q1= Qp* VP where VP= volumetric efficiency of thepump;
Q1 = Actual flow rate to motor
3. Motor theoretical flow rate ,QM= Q1* VM

where VM = volumetric efficiency of the motor

1. Motor capacity , CM= QM/ speed of motor ( m3/ rev)

2. Power delivered to motor, Phyd= System pressure*Q1 ( Watts)

3. Mechanical power generated, PMech = Phyd* VM* MM

where MM = mechanical efficiency of hydraulic motor

4. Actual Torque developed by motor, T a = PMech / 2 N
Where N = speed of motor inrps
8. Ideal torque , Ti= CM* P /2

9. Actual torque, Ta= Ti* MM

Problem 2. A Hydrostatic transmission operating at 70 bar pressure has the following

characteristic for the pump and the motor:

Pump: Capacity of pump, CP = 82 cm3/ rev ( pump displacement)

Volumetric efficiency of pump, VP = 82 %
Mechanical efficiency of pump, MP = 88
% Speed of pump , N = 500 rev / min
Motor: Capacity of motor, CM= ?
Volumetric efficiency of motor, VM = 92 %
Mechanical efficiency of motor, MM = 90
% Desired speed of motor , N = 400 rev /
min Actual Torque, Ta = ?

Solution :
 Pump theoretical flow rate, QP = pump displacement * speed
= 82 * 10 -06* 500 / 60
= 0.00068 m3 / sec
Actual flow rate to the motor , Q1 = QP* VP
= 0.00068 * 0.82
= 0. 00056 m3 / sec
Motor theoretical flow rate, QM= Q1* VM
= 0.00056 * 0.92
= 0. 000515 m3 / sec
Motor capacity, CM= QM/ speed ofmotor
= 0.000515 / 400/60
= 0.0000773 m3/ sec Ans
Power delivered to motor, Phyd = system pressure * Q1
= 70 * 105* 0.00056
=3920 Watts = 3.92 kW
Mechanical power generated, PMech = Phyd* VM* MM

= 3.92 * 0.92 * 0.90

= 3.246 kW

Actual Torque developed by motor, T a = PMech / 2 N

= 3.246*1000 / (2 *400 )
60
= 77.49N- m Ans
Ideal torque , Ti = CM* P / 2
= 0.0000773 * 70 *105 / 2
= 86.1 N-m
Actual torque, Ta= Ti* MM

= 86.1 * 0.90
= 77.49N–m Ans
ACCUMULATORS AND ACCUMULATOR CIRCUITS:

A hydraulic accumulator is a device that stores the potential energy of an

incompressible fluid held under pressure by an external source against some dynamic
force. The dynamic force can come three different sources : Gravity, Mechanical Springs,
and Compressed gases. The stored potential energy in the accumulator is a quick
secondary source of fluid power capable of doing useful work as required by the system.
There are three basic types of accumulator used in hydraulic system. They are:
1. Weight – Loaded, or gravity,type
2. Spring -Loadedtype
3. Gas – Loadedtype
1. Weight – LoadedAccumulator: This type consists of a vertical, heavy- wall steel
cylinder, which incorporates a piston with packing to pressure leakage ( Fig5.24)
. A dead weight is attached to the top of the piston. The force of gravity of the dead
weight provides the potential energy in the accumulator. This type of accumulator
creates a constant fluid pressure throughout the full volume output of the unit regardless
of the rate and quantity of output. The main disadvantage of this type of accumulator is
extremely large size and heavy weight which makes it unsuitable for mobile equipment.

Dead weight

Container
Piston

Packing
Fluid Port
Pressurized Fluid

Fig 5.24 Weight – Loaded accumulator

2. Spring – LoadedAccumulator: A spring loaded accumulator is similar to the

weight – loaded type except that the piston is preloaded with a spring as shown infig
5.25. The spring is the source of energy that acts against the piston, forcing the fluid into
the hydraulic system. The pressure generated by this type of accumulator depends on the
size and pre-loading of the spring. In addition, the pressure exerted on the fluid is not a
constant. The spring- loaded accumulator typically delivers a relatively small volume of
oil at low pressures. Thus, they tend to be heavy and large for high- pressure, large –
volume systems. This type of accumulator should not be used for applications requiring
high cycle rates because the spring will fatigue and lose its elasticity. The result is an
inoperative accumulator.

Container Spring
www.bookspar.com |VTU NOTES |QUESTION PAPERS |NEWS |RESULTS |FORUM
 Pressurized Fluid
Fluid flow

Fig 5.25 Spring - Type Accumulator

4. Gas Loaded Accumulator : Two main categories:

GasValve

Gas
Container

Fluid
Pressurized
Fluid flow port

Fig 5.26 Non Separator - Type Gas Accumulator

a. Non separator- Type Accumulator: The non separator type of accumulator

(fig 5.26)consists of a fully enclosed shell containing an oil port on the bottom
and a gas charging valve on the top. The gas is confined in the top and the oil at
the bottom of the shell. There is no physical separator between the gas and oil
and thus the gas pushes directly on oil. The main advantage of this type is its
ability to handle large volume of oil. The main disadvantage is absorption of
gas in the oil due to the lack of a separator. Absorption of gas in the oil also
makes the oil compressible, resulting in spongy operation of the hydraulic
actuators. This type must be installed vertically to keep the gas confined at the
top of theshell.
b. Separator – Type Accumulator: The commonly accepted design of gas
loaded accumulators is the separator type. In this type there is a physical barrier
between the gas and the oil. The three major type of separator accumulatorare
i) Piston type: The piston type of accumulator consists of a cylinder containinga
freely floating piston with proper seals. The piston serves as a barrier between
the gas and oil.(fig5.27). The main disadvantage of the piston types of
accumulator are that they are expensive to manufacture and have practical size
limitation. The principal advantage of the piston accumulator is its ability to
handle very high or low temperature system fluids through the utilization to
compatible O- ring seals.
 Gas Valve

Gas
Container

Piston

Pressurized Fluid
Fluid flow port

Fig 5.27 Separator - Type PistonAccumulator

ii) Diaphragm Accumulator: The diaphragm type accumulator consists of a

diaphragm, secured in the shell, which serves as an elastic barrier between theoil
and gas(fig5.28). A shutoff button, which is secured at the base of the
diaphragm, covers the inlet of the line connection when the diaphragm is fully
stretched. The primary advantage of this type of accumulator is its small weight-
to – volume ratio, which makes it suitable almost exclusively for mobile
applications. The restriction is on the deflection of thediaphragm

Gas Valve

Gas
Diaphragm

Pressurized Fluid

Fluid Valve
Fig 5.28 DiaphragmAccumulator
iii) Bladder type Accumulator: A bladder type- accumulator contains an
elastic barrier( bladder) between the oil and gas( fig5.29). The bladder is fitted in
the accumulator by means of a vulcanized gas- valve element and canbe
 installed or removed through the shell opening at the poppet valve. The poppet
valve closes the inlet when the accumulator bladder is fully expanded. This
prevents the bladder from being pressed into the opening. The greatest
advantage of this type of accumulator is the positive sealing between the gas and
oil chambers. Most widely used type ofaccumulator.

Gas Valve

Gas Bladder

Pressurized Fluid

Fluid Valve

Fig 5.29 Bladder type

AccumulatorAccumulatorCircuits :
1. Accumulator as a auxiliary power source:
 1
A 2 D

CV

P
 R
F
T
Fig 5.30. Accumulator as an auxiliary power source.
C = Double acting cylinder
A = Accumulator
P = Pump; T = Tank ; F = Filter
R = Relief Valve , CV = Check Valve
D =2-position, 4 way , Manually operated DCV

One of the most common application of accumulator is as an auxiliary power

source. The purpose of the accumulator in this application is to store oil delivered by the
pump during a portion of the work cycle. The accumulator then releases this stored oil on
demand to complete the cycle, thereby serving as a secondary power source to assist the
pump. In such a system where intermittent operations are performed, the use of an
accumulator results in being able to use a smaller size pump.
Figure 5.30 shows such a application in which a four way valve is used in
conjunction with an accumulator. When the four way valve is manually actuated, oil
flows from the accumulator to the blank end of the cylinder. This extends the piston until
it reaches the end of its stroke. While the desired operation is occurring ( the cylinder is
fully extended position ), the accumulator is being charged by the pump. The four way is
then deactivated for the retraction of the cylinder. Oil from both the pump and
accumulator is used to retract the cylinder rapidly. The check valve prevents the back
flow of oil from the accumulator when the pump is not working. The control signal for
the relief valve is obtained after the check valve, to control the combined pressure of
pump and the accumulator.

2. Accumulator as an emergency powersource:

C
A

1
0 A
 P
R

F
T

Fig 5.31. Accumulator as an Emergency power source.

C = Double acting cylinder
A = Accumulator
P = Pump; T = Tank ; F = Filter
R = Relief Valve , CV = Check Valve
D =2-position, 4 way , Manually operated DCV

In some hydraulic system, safety dictates that a cylinder be retracted even though
the normal supply of oil pressure is lost due to a pump or electrical power failure. Such
an application requires the use of an accumulator as an emergency power source.
Figure 5.31 shows such a application in which a solenoid actuated three way
valve is used in conjunction with an accumulator. When the three way valve is energized,
oil flows to the blank end of the cylinder and also through the check valve into the
accumulator and rod end of the cylinder. The accumulator charges as the cylinder
extends. If the pump fails due to an electrical failure, the solenoid will deenergize,
shifting the valve to the spring -offset position. Then the oil stored under pressure is
forced from the accumulator to the rod end of the cylinder. This retracts the cylinder to
the starting position. In normal working, when the solenoid is deenergized, the valve
shifts to the spring offset position. In this position the accumulator will retract the
cylinder.

3. Accumulator as a hydraulic shock absorber:

A1 A2
 1
2

P
R
F
T
Fig 5.32. Accumulator as an Shock Absorber
C = Double acting cylinder
A1, A2 = Accumulators
P = Pump; T = Tank ; F = Filter
R = Relief Valve ,
D = 2/4 Solenoid actuated, spring return DCV

One of the most important industrial application of accumulator is the elimination

or reduction of high pressure pulsation or hydraulic shock Hydraulic shock is caused by
the sudden stoppage, sudden impact load, or reversal with heavy loads. Hydraulic shock
load may be reduced considerably if the deceleration time of the flowing fluid mass can
be reduced. The accumulator ( Fig 5.32) should be installed as close to the shock source
as possible. Here 2 accumulators are installed near the entry to the cylinder. The oil from
the pump flow to the accumulator first and when accumulator is filled, the oil moves to
the cylinder and piston starts moving.