Chapter 11 Flow Control Valves and Circuits

Chapter 11 Flow Control Valves and Circuits
LEARNING OBJECTIVES
Upon completing this chapter, you should be able to:
Explain the working principle of hydraulic flow control valves.
Describe the operation of throttle valves and adjustable throttle valves.
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Differentiate the non-compensated and compensated flow control valves.

Explain the meter-in, meter-out, and bleed-off methods of speed control of hydraulic
actuators.
Compare and contrast the operating characteristics of various flow control circuits.
Understand and implement the regenerative function.
Explain the primary function of flow dividers.
Describe the priority flow dividers, as used in hydraulic systems.
Introduction
The previous chapter explained the directional control valves comprehensively. This chapter
presents a detailed account of another class of hydraulic valves, namely, the flow control valves.
The flow control is an important control aspect to be considered while designing a hydraulic
system, as it is the flow rate of the system fluid that controls the speed of the actuators in the
system. Broadly speaking, there are two ways of changing the flow rate in hydraulic systems: They
are (1) by using variable-displacement pumps (as in pump-controlled systems) and (2) by using
fixed-displacement pumps in conjunction with the flow control valves (as in valve-controlled
systems). In the pump-controlled system, the flow rate can be varied by adjusting the swash-plate
angle of the variable-displacement pump. The variable-displacement pump works well for a
hydraulic circuit with a single actuator. However, for many hydraulic applications, the
valve-controlled systems with throttle valves (or servo valves) are used for controlling the flow rate
of the system fluid, as they provide a fast response.
The most important function of the flow control valve is to offer a hydraulic resistance to the
flow of the system fluid and hence to control the volume of the fluid passing a given point in the
system. The flow control function can be realized by means of a controlled restriction in the path of
the fluid flow. The length of the restriction can be short or long. Accordingly, flow control devices
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are classified as either orifice valves or throttle valves respectively. It is to be noted that the
throttling action of a flow control valve is due to the division of the flow between the valve and the
system relief valve in a manner as explained in the following section.
Many variants of the flow control valves, such as flow control valves with integrated check
valves and pressure-compensated and temperature-compensated flow control valves are available
for obtaining many additional controls functions. Another class of flow control valves includes
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flow dividers for dividing a single flow into two or more flows. This chapter describes all these
types of flow control valves. This chapter also describes some typical flow control circuits
including speed control circuits of cylinders and motors and the regenerative circuit.
Concept of Flow Division

The circuits of Figures 11.1(a) and (b) explain the concept of the flow division in a hydraulic
circuit. Let us appreciate the idea here. Figure 11.1(a) shows a fixed-displacement pump delivering
a fixed amount of fluid per unit time (say 50 lpm [13.2 gpm]) to the cylinder through a throttle
valve. When the pump delivery is higher than the flow rate through the throttle valve, the resulting
excess flow cannot go anywhere. This excess flow results in a dangerous pressure build-up in the
line between the pump and the throttle valve, until the pump stalls, seals break, or a line blows.
Therefore, it is necessary to bypass or divide the excess flow by installing a pressure relief valve to
the flow line as shown in the modified Figure 11.1(b). That is; a part of the pump delivery flows
through the constant restriction of the throttle valve, and the excess delivery, if any, flows through
the pressure relief valve. This type of flow division is essential for obtaining the flow control in a
hydraulic circuit with a fixed-displacement pump.
Figure 11.1 | Circuit diagrams illustrating the concept of the flow division in a hydraulic system
with a flow control valve.
Types of Flow Control Valves

Flow control valves in hydraulic systems can be of many designs. An orifice is a flow control
device with a very short length of the restriction. A simple throttle valve is also a flow control
device that allows restricted flow in both directions of the flow when connected in a hydraulic
circuit. However, the length of the restriction in the throttle valve is comparatively long. An
important variant of the throttle valve is the one-way flow control valve. It is essentially a throttle
valve and a check valve in a parallel arrangement. This valve allows restricted flow in one direction
and unrestricted flow in the opposite direction. Other import considerations in the use of the flow
control valve are the amount of pressure drop across the valve and the effect of variations in
temperature on the flow rate. Pressure-compensated and temperature-compensated flow controls
allow precise volumetric flow control in hydraulic systems, irrespective of the variations in the
system pressure and temperature. Figure 11.2 shows the symbols for the basic flow control valves
in the fixed and adjustable modes of control. The figure also displays the symbols of many other
variants of the flow control valves, such as the one-way flow control valve, the
pressure-compensated flow control valve, and the orifice valve.
Figure 11.2 | Symbolic representations for various types of flow control valves.
The flow control valves are also available as line-mounted and cartridge versions. They are
made of a number of materials including stainless steel, brass, and carbon steel. The hardened and
ground working parts for a flow control valve provide accurate flow control and long working life.
The valve materials should not be susceptible to corrosion and other environmental conditions and
should operate correctly under the temperature extremes. When the flow control valve is to be used
in a hydraulic system, the following factors pertaining to the valve should be evaluated (1) the
pressure rating, (2) the pressure differential across the valve, (3) the flow rating, and (4) the
temperature rating. The details of the flow control valves are further explained in the following
sections.
Typical Applications of Throttle Valves

Throttle valves are used in a broad range of applications including conveyors, food processing
machines, and material-handling equipment. Figure 11.3 shows some important applications of the
flow control valves. The most important use of a flow control valve is to obtain the speed control of
a hydraulic actuator. The throttle valve can be installed upstream or downstream of the final control
element as shown in the part (a) and part (b) of the figure respectively. With the integration of a
check valve to a flow control valve, the flow in only one direction can be restricted, as in the
meter-in or meter-out method of speed control [See the part (c)]. With the fine adjustment and
complete shut-off features, flow control valves are used very frequently in pressure gauges for
damping the pressure surges that may appear within these gauges [See the part (d)]. The flow
control valves can be connected in series with or in parallel to hydraulic motors for controlling their
speeds [See the part (e)]. They can also be used as an integral part of other valves, such as
directional control valves, counterbalance valves, pressure reducing valves, and flow dividers.
Figure 11.3 | Partial hydraulic circuits demonstrating typical applications of throttle valves.
Orifice Valve
An orifice valve consists of a housing with a disk as shown in Figure 11.4. The disk is usually
embedded with a sharp-edge or a square-edge orifice. The function of the orifice is to control the
flow rate through a hydraulic system. The flow rate through the orifice depends on the size of the
opening, and hence the orifice area. As the restriction has negligible length, the flow rate through
the orifice valve is not affected by the viscosity of the system fluid. Orifice valves can be a fixed
type or a variable type. The adjustable orifice valve can be used for a simple and infinitely-variable
speed control application, where a constant-pressure condition exists. An orifice valve, especially
with a triangular inlet opening, permits a finer adjustment of the flow rate.
Figure 11.4 | Cross-sectional views of fixed orifice valves.

The flow rate through an orifice valve is proportional to the orifice area for a given pressure
drop. The relationships of the flow rate for the fixed orifice valve in the SI system units and the
English units are as follows:
In the SI system units:
Flow rate, Q = 1.41 x C x A x (P/SG)
In the English units:
Flow rate, Q = 38 x C x A x (P/SG)
Where,
Q = Flow rate (m3/s, gpm)
C = Flow coefficient (= 0.8 for sharp-edged orifice, = 0.6 for square-edged orifice)
A = Orifice area (m2, in2)
P = Pressure-drop across the orifice (kPa, psi)
SG = Specific gravity of the fluid (for mineral oil = 0.85 – 0.9)
Example 11.1: A sharp-edged orifice valve having a 0.019 m [¾ inch] diameter produces a
pressure drop of 550 kPa [80 psi] across the valve when fluid with a specific gravity of 0.9
flows through it. Find the flow rate through the valve.
Solution:
Given:
Pressure-drop (P) = 550 kPa [80 psi]
Orifice diameter, D = 0.019 m [¾ in]
Orifice area, A = .000284 m2 [0.44 in2]
Specific gravity, SG = 0.9
Capacity coefficient, C = 0.8 [For sharp-edged orifice]
Flow rate, Q = 1.41 x C x A x (P/SG)

= 1.41x 0.8 x 0.000284 x (550/0.9)
= 0.007896 m3/s
[Flow rate, Q = 38 x C x A x (P/SG)
= 38x0.8x0.44 x (80/0.9)
= 125.4 gpm]
Throttle Valves
A throttle valve, as used in a hydraulic system, is a device with a restriction that offers resistance to
the system fluid flowing through it. Precisely speaking, the throttle valve regulates the flow rate of
the fluid finely. According to the type of restriction, throttle valves are of two types. They are (1)
Fixed type and (2) Adjustable type. In the fixed-type throttle valve, the restriction is fixed, whereas
in the adjustable type throttle valve, the area of the restriction can be varied. The following sections
explain these types of throttle valves.
Throttle valve, Fixed-type: A fixed-type throttle valve consists of a housing with a constant
restriction of larger length, as shown in Figure 11.5. The valve, when connected in a hydraulic
system, is used to create a constant hydraulic resistance to the fluid flow through it, in either
direction. The pressure build-up ahead of the restriction permits a flow division. Therefore, the
flow rate through the system is reduced. A broad cross-section of the restriction represents a little
resistance to the flow, and a small cross-section of the restriction represents a high resistance to the
flow. Remember, a low hydraulic resistance causes a significant flow rate through the system.
Figure 11.5 | A cross-sectional view of a throttle valve, fixed-type.
As the system fluid flows through the constant restriction of the throttle valve, a part of the
hydraulic energy is converted to thermal energy on account of friction. This loss of energy appears
in the form of a pressure differential (p) across the restriction (or valve). The flow rate through the
throttle valve is a function of the following parameters (1) the cross-section of the restriction, (2)
the differential pressure (P) across the valve, and (3) the viscosity of the system fluid. As the
pressure drop across the valve fluctuates, depending on the variations of the connected load in the
system, the flow rate through the fixed-type throttle valve cannot be maintained constant.
The fixed-type throttle valve can be used for the simple speed control applications, where the
pressure differential across it remains constant and precise speeds are not essential. This type of
valves controls the speed of hydraulic cylinders in both directions of its motion.
Adjustable Throttle valves (Needle valves): There are two basic types of adjustable throttle valves
(Needle valves). They are (1) pressure-dependent throttle valves and (2) Pressure-compensated
throttle valves. In the pressure-dependent throttle valve, as used in a hydraulic system, the flow rate
of the system fluid varies appreciably with the pressure fluctuations across the valve. However, the
pressure-compensated throttle valve maintains a constant pressure differential across the valve.
Adjustable Throttle Valve, Pressure-dependent

A pressure-dependent adjustable throttle valve is to create an adjustable hydraulic resistance
without any compensation for the variations in pressure across the valve. In this type of throttle
valve, the flow rate through it varies appreciably for the same setting due to the pressure
fluctuations across the valve. Figure 11.6 gives the cross-sectional view of the adjustable throttle
valve. It consists of an orifice whose cross-section can be controlled by an externally adjustable
needle-shaped plunger. The flow through the controlled cross-section can be metered precisely by
the pointed needle. However, it is capable of handling relatively small flow rates only.
Figure 11.6 | A cross-sectional view of an adjustable throttle valve, pressure-dependent.
The flow rate through the throttle valve is a function of the following (1) the cross-section of the
orifice, (2) the differential pressure across the valve and (3) the viscosity of the fluid passing
through the valve. In a simple throttle valve, the differential pressure across the valve increases as
the flow rate through it increases. Because of this operating phenomenon, pressure-depended flow
control valves cannot be used for the precise speed control applications. This type of throttle valve
can be used in applications where the pressure fluctuations are minimal, as in lifting platforms and
clamping fixtures. For the precise speed control applications, the pressure-compensated throttle
valves are most appropriate.
Compensated Flow Controls Valves

Flow control valves can be of the non-compensated type or the compensated type. In the
non-compensated type of flow control valves, the flow rate across each valve varies with the
variation in the pressure drop across it. In the compensated type, the valve automatically adjusts to
the changes in the pressure or temperature condition in the valve to produce a constant flow rate.
Pressure-compensated Adjustable Throttle Valve: As you are aware, the flow rate through an
elementary throttle valve varies appreciably with the same setting due to the pressure fluctuations
at the inlet or the outlet of the valve. However, a pressure-compensated throttle valve maintains a
constant pressure differential across it, irrespective of the fluctuations in the connected load or
valve inlet pressure, with the help of its pressure-regulating piston.
A pressure-compensated adjustable throttle valve, as shown in Figure 11.7, consists of (1) an
adjustable throttling section, and (2) a pressure-regulating section. Assume that the valve is
connected to a hydraulic system. The throttling section controls the flow rate of the system fluid,
and the pressure-regulating section with a spring-biased compensator spool regulates the pressure
across the valve. The setting of the valve’s orifice area determines the flow rate through it. The
pressure-regulating section consists of the spring-biased piston. Initially, the passage through the
pressure regulator is fully open. However, the piston adjusts its position continually when the flow
rate tends to vary, so as to maintain the flow through it a constant. The concept of the pressure
compensation is proved mathematically in the following paragraphs.
Figure 11.7 | A schematic view of a pressure-compensated flow control valve.

Let P1 be the inlet pressure, P2 be the pressure downstream of the throttle section, and P3 be the
outlet pressure, as shown in Figure 11.7. Let A1 and A2 be the areas on either side of the pressure
regulating piston. Let the spring force be FS. The regulating piston is loaded from the left by the
force F1, which is a function of the pressures P1 and P2, and the piston areas A1 and A2.
That is, F1 = P1 x A1 + P2 x A2
The regulating piston is loaded from the right by a force F2, which is a function of the pressure P
2, the piston areas A1 and A2, and the spring force FS.
That is, F2 = P2 x A2 + P2 x A1 + FS
Forces F1 and F2 acting on the regulating piston must be in equilibrium. Therefore, F1 = F2.
That is, P1 x A1 + P2 x A2 = P2 x A2 + P2 x A1 + FS
Or, P1 x A1 = P2 x A1 + FS
Or, P1 x A1 - P2 x A1 = FS
Or, (P1 – P2) x A1 = FS
Or, (P1 – P2) = FS/ A1
Or, P = FS/ A1
As FS and A1 are constant, P must also be constant. When P remains constant irrespective of the
pressure fluctuations in the valve, the flow rate through the valve also tends to stay constant.
Temperature Compensation: The variations in the temperature of the fluid in a hydraulic system
tend to alter the viscosity of the system fluid. As the fluid viscosity varies, the flow rate through a
throttle valve, connected as a part of the system, also changes for a given setting of the valve. For
many hydraulic systems, the flow rate of the system fluid must be maintained constant, irrespective
of the temperature fluctuations in the system. For such applications, the temperature-compensated
throttle valves can be used to compensate for the fluctuation in the temperature and the consequent
changes in the flow rates.
In a typical design, the temperature-compensated throttle valve uses a sharp-edged metering
orifice in which the flow rate through the orifice is not sensitive to the variations in the viscosity of
the fluid. In some other type of design, the temperature-compensated throttle valve uses an orifice
with dissimilar metals to adjust its area automatically, in response to the variations in the system
temperature, so as to maintain a constant flow rate through the valve.
Flow Rate through Throttle Valves

The flow rate trough a needle (throttle) valve is substantially influenced by the pressure drop across
the valve. As given for the directional control valves, the general equations for the flow rate can be
expressed in the SI system unit as well as in the English unit are as follows:
In the SI system units,
Flow rate, Q = Kv x (P/SG)
In the English units,

Flow rate, Q = Cv x (P/SG)
Where,
Q is flow rate in lpm, gpm
P is the pressure drop developed across the valve in kPa, psi
Kv [Cv] is the capacity coefficient in lpm/kPa, [gpm/psi]
SG is the fluid’s specific gravity
The value of flow coefficient Kv (Cv) for a flow control valve in its fully open position is
determined experimentally and is listed as the rated Kv (Cv) in its manufacturer’s catalogs.
Example: 11.2: Calculate the capacity coefficient of a flow control valve that experiences a
pressure drop of 400 kPa [58 psi] for the flow rate of 114 lpm [30 gpm]. The hydraulic fluid
passing through the valve has the specific gravity of 0.9.
Solution:
Given:
Pressure-drop, P = 400 kPa [58 psi]
Flow rate, Q = 114 lpm [25 gpm]
Specific gravity, SG = 0.9
Capacity coefficient, Kv = Q/(P/SG)= 114 /(400/0.9)= 5.4 lpm/kPa
[Capacity coefficient, Cv = Q/(P/SG)= 30 /(58/0.9) = 3.74 gpm/psi]
Test Your Knowledge #11.1

1. The speed of an actuator in a hydraulic system with a fixed-displacement pump can be
controlled by using a ______________ valve.
2. A(n) _______________valve is a flow control valve unaffected by the viscosity of the
fluid passing through it.
3. In a simple throttle valve, the differential pressure across the valve increases as the
________ through it increases.
4. The flow rate through a throttle valve depends on the area of the cross-section of the valve
restriction, the _____________ across the valve and the viscosity of the fluid passing
through the valve.
5. A _____________ type flow control valve maintains a constant flow rate independent of
the changes in the applied load or the inlet pressure.
[Choose from: Differential pressure, Directional control, Flow control, Flow rate, Orifice, Pressure
compensating, Pressure control, Temperature compensating, Throttle]
One-way Flow control Valve
Hydraulic flow control valves, such as the orifice valves and the elementary throttle valves, as
discussed in the previous sections provide the same flow restriction in either direction of the fluid
flow. A one-way flow control valve provides a restricted flow of the fluid in one direction and an
unrestricted flow in the reverse direction. The one-way flow control feature is important when a
direction-sensitive speed control of the associated actuator is required.
The one-way flow control valve consists of a throttling section and a check valve section, both
integrated into its valve body in a parallel arrangement. It is also known as throttle check valve.
The annular gap at the throttling point can be controlled by turning the throttling screw. Figure 11.8
gives the schematic diagrams representing the two positions of the one-way flow control valve.
Figure 11.8 | Schematic diagrams showing two critical positions of a one-way flow control valve.
Consider that the throttle check valve is connected to a hydraulic system. The check valve
blocks the system flow in one direction forcing the fluid to flow through the controlled
cross-section as shown in Figure 11.8(a). Hence, the flow is throttled, and the flow rate is
controlled, in that direction. In the opposite direction, the fluid flows freely through the opened
check valve without any restriction, as shown in Figure 11.8(b). This valve is used, whenever a
direction-sensitive speed control of a hydraulic actuator is required as in clamping applications.
Speed Control of a Cylinder using a One-way Flow Control Valve

The control requirement of an actuator in a hydraulic system can be realized by using the flow
control valve (throttle valve). Usually, this valve is installed in line between the actuator and its
final control element. In order to get a direction-sensitive speed control of the actuator, it is
necessary to use the one-way flow control valve (throttle check valve), instead of the simple
throttle valve. According to the way the throttle check valve is placed in the system, there are two
methods of the direction-sensitive speed control of the actuator. These are (1) meter-in method and
(2) meter-out method. Apart from these two methods, another method known as the bleed-off
method can also be used for getting the speed control. In this method, a throttle valve is connected
in between the actuator and the system reservoir. All these basic methods can meet the varying
flow-control demands for systems with positive as well as negative loads. The following sections
further explain these methods.
Meter-in Method: Consider that the speed of a double-acting hydraulic cylinder is to be controlled
using the meter-in method. In the meter-in method, the speed of the cylinder in one direction can be
controlled by restricting the system flow into the cylinder and allowing unrestricted flow away
from the cylinder. The meter-in circuit is ideal for applications where an external load opposes the
motion of the cylinder, thus offering a definite resistance to the flow during the controlled stroke of
the cylinder. This method gives a finer speed control as compared to other methods of speed
control. However, this method cannot provide accurate speed control of an actuator under the
negative load condition. Another disadvantage of this method is that the associated pump is always
operating at the maximum pressure setting of the pressure relief valve in the system. Some
applications employing the meter-in method of speed control are: feeding grinder tables, welding
machines, milling machines, and rotary hydraulic motor drives. You may refer to Example 11.3 for
the explanation of a circuit using this method of speed control.
Example 11.3: Develop an appropriate circuit for the speed control of a double-acting
hydraulic cylinder during its forward stroke, with an opposing external load.
Solution:
As the forward motion of the double-acting hydraulic cylinder is opposed by an external load
offering a positive resistance to the system flow, the meter-in method is appropriate for the speed
control of the cylinder. Figure 11.9 shows the circuit arrangement for the speed control of the
cylinder. A throttle check valve is installed in between the piston-side port of the cylinder and the
associated DC valve, in such a way that the fluid entering the cylinder at the piston side port is
throttled. This control action results in the speed reduction of the cylinder during its forward stroke.
During the retraction stroke, the fluid in the cylinder can pass freely to the system reservoir through
the opened check valve, and hence, the cylinder can retract with its standard speed.
Figure 11.9 | A circuit showing the meter-in method of flow control for controlling the speed of the
forward motion of a hydraulic cylinder. (Example 11.3)
Meter-out Method: Consider that the speed of a double-acting hydraulic cylinder is to be controlled
using the meter-out method. In the meter-out method, the speed of the cylinder in a given direction
can be controlled by restricting the flow away from the cylinder and allowing an unrestricted flow
into the cylinder. This method maintains a constant backpressure while the cylinder is moving and
prevents its lunging if the load connected to the cylinder drops suddenly. This method, therefore,
can be used in actuator systems with overrunning (negative) loads (e.g. crane booms and winches).
However, there is a possibility of pressure-intensification at the piston-rod side of the cylinder
while using the meter-out control for its forward stroke. For example, let the pressure on the piston
side of a cylinder with an area ratio of 2:1, is 100 bar [1450 psi], and then the pressure on the
piston-rod side can go up to 200 bar [2900] psi. Another disadvantage of the meter-out method of
speed control is that the associated pump is always acting against the maximum pressure setting of
the system pressure relief valve. You may refer to Example 11.4 for further explanation of this
method.
Example 11.4: Develop an appropriate circuit for the speed control during the forward stroke
of a vertically-mounted double-acting hydraulic cylinder where a heavy weight is pulling down
the cylinder piston. What is the way to get speed control during the return stroke also?
Solution:
As the weight is pulling the piston of the double-acting hydraulic cylinder down, the meter-out
method is appropriate for the speed control of the cylinder to prevent its lunging. Figure 11.10
gives the circuit arrangement for the meter-out method of speed control for the cylinder. In this
method, a throttle-check valve is installed in between the piston-rod-side port of the cylinder and its
main directional control valve, in such a way that it throttles the fluid leaving the cylinder through
the piston-rod side. This results in the speed reduction during the forward stroke of the cylinder.
During the return stroke, the fluid from the pump can pass freely through the opened check valve
on its way to the cylinder, and hence, the cylinder can retract with its normal speed.
Figure 11.10 | A circuit showing the meter-out method of flow control for controlling the speed of
the forward motion of a hydraulic cylinder. (Example 11.4)
For obtaining the speed control during the return stroke of the cylinder, another throttle check
valve can be installed in the line between the piston side port and the main control valve in such a
way that the valve throttles the fluid leaving the cylinder through the piston side port. (Not shown)
Bleed-Off Method: Another method of speed control of a hydraulic actuator (cylinder) is the
bleed-off control (or bypass flow control). In this method, one end of the flow control valve is
connected to the cylinder as shown in the circuit of Figure 11.11. The other end of the bleed-off
valve is directly connected to the system reservoir. A measured part of the delivered fluid intended
for the cylinder can be bled off to the reservoir through the throttle valve, and the remaining part
goes into the cylinder. As the pressure on the system pump is only high enough to move the load,
this type of circuit usually results in the generation of less heat and hence tends to be more
energy-efficient than the meter-in and meter-out methods. However, the bleed-off control cannot
maintain a precise speed regulation if the flow at the inlet line changes. Moreover, this method of
speed control can only be used to control the speed of one actuator at a time, and this method
cannot be used with actuators having overrunning loads.
Figure 11.11 | A partial hydraulic circuit showing the bleed-off method of speed control of a
hydraulic cylinder.
Other Variants of Flow Control Valves
Accurate control of flow and pressure is necessary for many critical hydraulic applications, such as
hammer and excavator control systems. Therefore, a range of flow control valves with basic types,
such as the restrictive type, the bypass type, and the priority type, are designed to provide a number
of additional flow control functions. The restrictive type is a plain flow regulator that controls the
flow regardless of the changes in the downstream pressure. The bypass type flow regulator is
provided with an integrated relief valve that senses the pressure from the regulated port and
relieving the excess flow to the associated reservoir. The priority flow regulator gives priority to a
set value of the flow, with the excess flow passing through the bypass. Figure 11.12 provides the
symbolic representations of these types of flow control valves.
Figure 11.12 | Symbolic representations of many variants of flow control valves.
Regenerative Circuit
In an earlier chapter, we have learned that a typical conventional double-acting hydraulic cylinder
with piston area ‘Ap’ and piston-rod area ‘Ar’ produces somewhat greater speed when retracting
than when extending provided that the pump flow remains constant. However, many hydraulic
circuits require faster extension stroke to reduce their overall cycle times. A regenerative circuit can
be employed to increase the speed of a cylinder during its extension stroke. The idea of the
regenerative circuit is explained with the help of Figure 11.13. The circuit consists of the cylinder
powered by a fixed-displacement pump with a flow rate ‘QP’ and controlled by a 3/2-DC valve.
The lines to the ports of the cylinder are connected in parallel.
Figure 11.13 | Two critical positions of a regenerative hydraulic circuit.
During the forward stroke of the cylinder, the fluid from the pump (QP) flows to the cap end of
the cylinder through the DC valve and the flow from the piston-rod end (Q R) regenerates with the
pump flow. During its forward stroke, the total flow (QT) to the cap end of the cylinder is the sum
of QP and QR.
That is,
QT= QP+ QR
Therefore, the pump flow rate QP is given by:
QP= QT - QR
As we are aware, the total flow rate (QT) is the product of the piston area (AP) and the extension
speed (vext) and the regenerative flow rate (QR) is the product of the active area on the piston-rod
side (that is, AP – Ar) and the extension speed, we have,
QP = QT- QR = APx vext- (AP– Ar) x vext = Arx vextTherefore, vext = QP/Ar
The equation mentioned above suggests that the speed of the extension stroke equals the pump
flow rate divided by the piston-rod area. Thus, a small rod area provides a significant extension
speed.
Ratio of Extension and Retraction Speeds: The ratio of the extension speed (vext) and the retraction
speed (vret) of a hydraulic cylinder can be related to the area ratio (Ap/Ar) of the cylinder. The area
ratio can be calculated in the following manner:
Retraction speed, vret= QP/(AP– Ar)
Therefore, vext/ vret= (AP– Ar)/ Arvext/ vret= (AP– Ar) –1
The equation mentioned above suggests that higher the ratio of the piston area to the piston-rod
area of the cylinder, the greater would be the ratio of its extending speed to its retraction speed. For
the particular case of a cylinder with its piston area equals to two times its piston-rod area, the
extension and retraction speeds of the cylinder would remain the same.
Load-carrying Capacity: The load-carrying capacity of the regenerative hydraulic cylinder during
its extension stroke is less than that would have obtained from a regular double-acting hydraulic
cylinder. The load-carrying capacity of the cylinder during its extension stroke equals the system
pressure times the piston-rod area rather than the piston area. This fact is because the pressure acts
on both sides of the piston during the extension stroke of the cylinder.
Example 11.5: A double acting hydraulic cylinder is used in the standard regenerative circuit
with a fixed-displacement pump, a pressure relief valve, and a 3/2-DC valve. The system
pressure is set at 200 bar [2900 psi]. The piston area is 130 cm2 [2 in2] and the piston-rod area
is 65 cm2 [1 in2]. The pump discharge is 0.0016 m3/s [15.4 gpm]. Find the speed and the load
carrying capacity for (1) the extension stroke and (2) the retraction stroke, of the cylinder.
Solution:
Given:
Pressure, P =200 bar [2900 psi]
Piston area, Aext = 20.26 cm2 [3.14 in2]
Rod area, Arod =10.13 cm2 [1.57 in2]
Flow rate, Q = 14.75 lpm =2.46x10-4 m3/s [15 in3/s]
Rod_side area, Aret =Aext- Arod
=(20.26 – 10.13) = 10.13 cm2

[=(3.14 – 1.57) =1.57 in2]
Extension speed, vext =Q/Arod
=0.000246/10.13x10-4 = 0.24 m/s

[=15/1.57 = 9.55 in/s]
Retraction speed, vret =Q/Aret
=0.000246 / (10.13) = 0.24 m/s

[15/ (1.57) = 9.55 in/s]
Load carrying capacity, forward stroke = PxArod

=200x105x10.13x10-4 = 20260 N
[=2900x1.57=4553 lb]
Load carrying capacity, return stroke =PxAret
=200x105x10.13x10-4 = 20260 N
[=2900x1.57 =4553 lb]
Hydraulic Motor Speed Control Circuits

The speed of hydraulic motors can be controlled by using the flow control valves. However, precise
control of the speed of a hydraulic motor is difficult to obtain, on account of excessive motor
slippage. The obtainable speed range depends on the type of motors used. For example, the gear
and vane type motors provide a narrow speed range, whereas, the piston motors provide a wider
speed range. There are many types of speed control methods employed for the hydraulic motors.
Apart from other factors, the performance of hydraulic motors also depends on the type of speed
control methods used. Two principal methods are examined below.
Series Meter-in Speed Control: Figure 11.14(a) gives the self-explanatory circuit for the series
meter-in speed control of a bi-directional hydraulic motor. This method provides a broad range of
speeds but tends to produce more heat in the system fluid.
Figure 11.14 | Two circuits showing hydraulic motor speed control schemes.
Meter-out Bypass Speed Control: Figure 11.14(b) gives the self-explanatory circuit for the
meter-out bypass speed control of a bi-directional hydraulic motor. This method is an effective
method of controlling the speed of a hydraulic motor over a broad range.
Flow Divider/Combiner
A flow divider is a hydraulic device that divides a single inlet flow into two or more prescribed
outlet flows regardless of the load pressures at the outlet ports. A flow combiner is a hydraulic
device that combines two or more flows into a single flow. There are two common types of flow
divider/combiner devices. They are (1) rotary type and (2) sliding-spool type.
Rotary Flow Divider (or Combiner):

A hydraulic rotary flow divider (or combiner) makes use of two coupled identical hydraulic gear
motors/pumps, as shown in Figure 11.15(a). As these machines are coupled together on the same
drive shaft, they run at the same speed. These motors control the flow rates through their outlets.
The main advantage of the rotary flow dividers is that the contaminants or the dirt in the fluid has
little effect on their performance due to the wide clearance between the gears and the housing of
each machine. However, their disadvantages are that they are noisy and less accurate due to the
internal leakages.
Figure 11.15 | Circuit diagrams showing the basic representations of hydraulic flow dividers.
Sliding-Spool Flow Divider: A sliding-spool type flow divider is a form of pressure-compensated

flow control valve that takes a volume of fluid from the pump and divides the flow between two
functions. Moreover, in the reverse direction, it recombines the flows. It can be designed to split the
flow to its outlets, either equally or by a certain percentage to give priority to some key components
over other less critical components. Figure 11.15(b) shows the basic representation of the flow
divider with one inlet and two outlets. The inlet flow passes through the orifices and divides the
flow. The sliding spool dividers are more accurate than the rotary flow dividers. However, they are
adversely affected by the contaminants in the system fluid.
The sliding-spool type hydraulic flow dividers are designed in the priority, the proportional
priority, and the load sensing versions. This type of flow dividers is available in a broad range of
flow ratings and relief settings. Many sliding-spool flow dividers are also available in adjustable
and non-adjustable versions. These large options allow a designer to make multiple configurations
as per the requirements of the applications. The load sensing priority valves can provide a
dependable flow on demand for getting the load sensing steering, braking, or other priority services
while allowing the excess flow to be used for auxiliary functions. Applications include tractors,
motor graders, lift trucks, and backhoe/loaders. The following sections present a brief explanation
of some types of priority valves.
Basic Priority Valve:

The function of the priority valve within a hydraulic system is to permit the flow to certain
functions on high priority when the system pressure goes beyond a specified level. In Figure 11.16,
shows a simple arrangement of a priority valve with an inlet, and two outlets ‘A’ and ‘B’. In this
valve, the flow enters through the inlet port and goes out through the outlet ports A and B. As the
pressure at the inlet side of the valve drops, the piston moves to the left, thus reducing the flow area
through the port A. Eventually when the pressure at the inlet is low enough, the flow area through
the port A becomes zero and consequently all the available flow goes through the port B. This fact
can be utilized for obtaining two sets of functions with one set having a higher priority and the
second set having a lower priority. The higher priority functions can receive the flow through the
port B while the lower priority services can receive the flow through the port A. It is to be noted
that the flow rates through the ports A and B can be customized based on its port sizes and by
controlling the critical flow-related dimensions of the piston.
Figure 11.16 | A schematic diagram of a basic priority valve.
Priority Valve with Built-in Relief: Figure 11.17 shows another type of priority valve with a single
inlet and two outlets ‘A’ and ‘B’ and a spool with appropriate flow-related dimensions. It monitors
downstream pressure in both lines. The outlet A is the fixed (or variable) flow outlet, and the outlet
B is the excess flow outlet. The orifice at the outlet A presets the fluid flow through it. A pressure
relief valve (PRV) is also provided in the controlled flow side. As the fluid enters through the inlet,
the fluid passes through the outlet A on priority. If there is excess flow due to the variation in the
pump flow or due to any other reason, then the pressure builds on the right-hand side of the flow
control spool. If the pressure is sufficient enough, the spool moves to the left permitting the excess
flow to pass through the excess-flow outlet. The valve also consists of a built-in relief section to
protect the associated system against any excess pressure. The symbol is an approximate
representation as there is no standard ISO or ANSI symbol for the valve.
Figure 11.17 | A cross-sectional view of the priority valve with relief.
Example 11.6: Develop a control circuit to synchronize the movement of two actuators under
different load conditions, by dividing the pump flow during the forward motion of the
cylinders and recombine the flows during return motion of the cylinders. What are the
advantages of this circuit?
Solution:
The circuit can be developed by using a flow divider/combiner as shown in Figure 11.18. The
pressure compensation, if employed, ensures the maintenance of equal flow during the forward or
reverse flow, over an extensive range of pressure variations. The flow divider operates over a
narrow bandwidth rather than at one set point. Therefore, flow variations in the secondary circuits
are likely. With this system, the pump capacity must be high enough to operate all the functions
simultaneously. It must be capable of supplying enough fluid at the maximum rated pressure level
of the highest function.
Figure 11.18 | A hydraulic circuit for synchronizing the motion of two hydraulic cylinders using a
flow divider. (Example 11.6).
Example 11.7: Develop a control circuit for controlling two bi-directional hydraulic motors
connected in parallel, through the flow divider. Assume that the load on each motor is the
same as that of the other.
Solution:
Figure 11.19 gives the circuit for controlling two bi-directional hydraulic motors connected in
parallel. Each motor is controlled by a 4/3-DC open-center valve. A flow divider divides the pump
flow into two and delivers the flows to the motors.
Figure 11.19 | A hydraulic circuit for controlling two hydraulic motors connected in parallel using a
flow divider. (Example 11.7)
Test Your Knowledge #11.2

1. The ______ method of speed control of hydraulic actuators is the best for negative loads.
2. ______ is the best method for obtaining the finer control of the speed of a hydraulic
cylinder coupled to a positive load.
3. The ______ method of speed control of hydraulic actuators is the most energy-efficient.
4. A _____________ circuit can be used to obtain the same speed for the forward motion as
that of the return motion of a typical hydraulic cylinder.
5. A _____________ is a hydraulic device used to divide a single inlet flow into two or more
prescribed outlet flows.
[Choose from: Bleed-off, Bypass type, Flow divider, Meter-in, Meter-out, Priority valve,
Regenerative, Restrictive type]
Objective Type Questions

1. The flow control in a hydraulic circuit is associated with:
a) Direction control of actuators
b) Speed control of actuators
c) Load sensing
d) Pressure setting
2. The volume of fluid passing through a hydraulic circuit can be controlled by means of a:
a) Poppet
b) Pilot valve
c) Metering orifice
d) Spool
3. Which of the following is the correct statement?

a) A non-compensated type flow control valve automatically adjusts to the changes in
pressure to produce a constant flow rate.
b) In the meter-out method of speed control, the flow to a cylinder is restricted.
c) A meter-in speed control circuit is ideal for applications where an external load opposes
the motion of the associated hydraulic cylinder.
d) The bleed-off control is a method to release air trapped in hydraulic systems.
4. What are the factors the flow rate through a throttle valve dependent on primarily?
a) Cross-section of the valve orifice, differential pressure across the valve, fluid density
b) Cross-section of the valve orifice, differential pressure across the valve, fluid viscosity
c) Shape of the valve orifice, system pressure, viscosity
d) Cross-section of orifice, system pressure, viscosity
5. In which of the following speed control methods, the fluid leaving a hydraulic actuator is only
throttled?
a) Meter-in
b) Meter-out
c) Bleed-off
d) Bypass throttling
6. Identify the symbol in Figure 11.20:
Figure 11.20 | Question 6

a) Throttle valve
b) One-way flow control valve
c) Flow control valve with pressure compensation
d) Throttle valve with bypass
7. In a conventional double-acting hydraulic cylinder the speed of the forward stroke is:
a) less than the speed of return stroke
b) equal to the speed of return stroke
c) greater than the speed of return stroke
d) more uniform than the speed of return stroke.
8. Identify the symbol in Figure 11.21:

Figure 11.21 | Question 8

a) Throttle valve
b) One-way flow control valve
c) Pressure compensated flow control valve
d) Orifice valve
9.
9. For a hydraulic cylinder used in regenerative circuit, the extension speed would be equal to
retraction speed if the ratio of piston area to piston-rod area is
a) 1:1
b) 1.5:1
c) 2:1
d) 2.5:1
Questions:
1. Explain the different ways in which the flow rate of fluids in hydraulic systems can be varied.
2. Mention three ways to control the speed of hydraulic actuators? What are their relative
advantages and disadvantages?
3. Mention the primary function of a flow control valve used in a hydraulic system.
4. Explain the concept of flow division with respect to the use of flow control valves in hydraulic
systems with a neat sketch.
5. Draw the symbols for (1) Adjustable needle valve, (2) Pressure-compensated throttle valve, (3)
One-way flow control valve and (4) Orifice valve.
6. Explain how the flow control is achieved with hydraulic systems.
7. List different types of flow control valves available for hydraulic applications?
8. Classify hydraulic flow control valves.
9. Which is the hydraulic flow control valve that is least affected by the viscosity changes?
Explain.
10. What is the one-way flow control valve, as used in hydraulic systems?
11. Differentiate the throttle valves and the orifice valves, as used in hydraulic systems.
12. Differentiate the pressure-dependent and the pressure-compensated type of hydraulic flow
control valves.
13. List some applications of the flow control valves and briefly, explain with necessary sketches.
14. What are the factors the flow rate through a throttle valve depends on?
15. Explain the operation of the following: (1) Throttle valve, (2) Adjustable throttle valve.
16. Draw the symbol for a pressure-compensated flow control valve?
17. Explain the constructional features of a pressure-compensated flow control valve.
18. How can the pressure compensation be achieved by flow control valves? Explain.
19. Describe the operation of the one-way flow control valve used in hydraulic systems and
mention its applications.
20. Describe the working of a flow control valve with an integrated check valve.
21. Differentiate the meter-in and the meter-out methods of speed control as used in hydraulic
systems.
22. Explain the meter-in method of speed control of a double acting cylinder with a suitable circuit
diagram.
23. Explain the meter-out method of speed control of a double acting cylinder with an appropriate
23.
circuit diagram.
24. Mention three different methods employed for controlling the speed of hydraulic double-acting
cylinders.
25. What is the purpose of the combined flow control valve and check valve?
26. What is the meter-in circuit as used in hydraulic systems? What are its limitations?
27. What is the meter-out circuit as used in hydraulic systems? What are its limitations?
28. Explain the function and the use of the bleed-off circuit as used in hydraulic systems.
29. Briefly, explain the idea of the bleed-off speed control method of a hydraulic cylinder with a
simple circuit diagram.
30. Develop a control circuit for the bleed-off method of speed control of a double-acting cylinder
during the extension stroke. Use a fixed-displacement pump to deliver the fluid and a PRV to
limit the pressure in the system.
31. Contrast the operating characteristics of the meter-in, meter-out, and bleed-off flow control
circuits.
32. What is the purpose of the regenerative circuit in hydraulic systems?
33. How is the rapid cylinder motion generated in a regenerative circuit?
34. In order to achieve the same speed for the forward and return motion of a hydraulic cylinder,
what kind of circuit you construct? Explain the operation of the circuit.
35. Explain with a circuit for the shaping operation how fast approach, slow feed, and rapid return
can be achieved.
36. Develop the regenerative control circuit for the rapid forward stroke of a double-acting
hydraulic cylinder. Use a tandem-centre 4/3-DC valve as a final control element.
37. What is a flow divider? How can it be used in hydraulic circuits?
38. Explain the elementary priority valve with a neat sketch.
39. Develop a hydraulic circuit for the following requirements: (1) the speeds of hydraulic piston
in both directions should be the same, (2) the piston should stop any desired position, (3)
systems pressure should be set to 150 bar and (4) system should have facility for cleaning the
hydraulic fluid at least three different locations in the circuit.
Numerical Problems
1. What is the percentage increase in the pressure drop across a hydraulic flow control valve, if
the flow through the valve is doubled? {Ans: Ans: 300%}

2. A hydraulic valve has an experimentally determined Cv rating of 8 gpm/psi. The valve is
designed to permit a 20 gpm of a fluid to flow through it. The specific gravity (SG) of the fluid
can be taken as 8.5. Calculate the anticipated pressure drop across the valve. {Ans: 53.125 psi}
3. A cylinder with an area ratio of 2:1 generates an extension speed of 0.5 m/s [20 in/s], when
connected in a hydraulic system. What is the return speed of the cylinder? {Ans: 0.5 m/s [20
in/s]}
4. A double acting hydraulic actuator is used in a regenerative circuit with a pump, pressure relief
4.
valve, and a 3/2-DC valve. The system pressure is set at 210 bar [3046 psi]. The piston area is
0.82 m2 [1256 in2] and piston-rod area is 0.41 cm2 [628 in2]. The pump flow is 0.00126 m3/s
[20 gpm]. Find the actuator speed and load carrying capacity for (1) extending speed and (2)
retracting speed. {Ans: Extension stroke: 0.003 m/s, 8610000 N, [0.123 in/s, 1912888 lb,
Retraction stroke: 0.003 m/s, 8610000 N, [0.123 in/s, 1912888 lb]}.
5. A cylinder with a piston area of 0.00786 m2 [12 in2] and a piston-rod area of 0.00393 m2 [6 in2
] is connected to a hydraulic system with a pump delivering 0.00123 m3/s. What is the speed
developed by the cylinder during the extension stroke, when connected to a hydraulic system
under (1) standard mode and (2) in regenerative mode? {Ans: 0.156 m/s, 0.3 m/s, [6.25 in/s,
12.3 in/s]}
6. A cylinder with a piston area of 0.00786 m2 [12 in2] and a piston-rod area of 0.00393 m2 [6 in2
] is connected to a hydraulic system with a pump delivering flow at a maximum pressure of
105 bar [1523 psi]. What is the cylinder's load carrying capacity during the extension stroke,
when connected to a hydraulic system under (1) normal mode and (2) in regenerative mode?
{Ans: 82530 N, 41265 N, [18276 lb, 9138 lb]}
7. A d/a hydraulic cylinder is used in a regenerative circuit with a pump, pressure relief valve,
and a 3/2-DC valve. The system pressure is set at 105 bar [1523 psi]. The piston area is
0.00786 m2 [12 in2] and piston-rod area is 0.00314 m2 [4.8 in2]. The pump flow is 0.00123 m3
/s [19.5 gpm]. Find the cylinder's speed and load carrying capacity for (1) extending speed and
(2) retracting speed. {Ans: Extension stroke: 0.39 m/s, 3297 N, [15.63 in/s, 7310 lb, Retraction
stroke: 0.26 m/s, 49560 N, [10.42 in/s, 10966 lb]}.
References
1. Anthony Esposito, Fluid power with Applications, 6th Edition, Prentice-Hall of India, 2006.
2. Article on: ‘Flow control valves’, Hydraulics & Pneumatics webmaster, Penton Media Inc.,
USA.
3. Article on: ‘Principles of Hydraulics v 2.0’, Content provider U.S. Army, Web Developer:
David L. Heiserman, Publisher: SweetHaven Publishing Services.
4. Bulletin on: ‘HANDBOOK FOR CONTROL VALVE SIZING’, PARCOL S.p.A. ITALY.
5. Catalog on ‘Flow Control Valves’ No. HY 15-3502/US, Parker Hannifin Corporation,
Hydraulic Cartridge Systems, USA.

6. Catalog on: ‘Flow Dividers’, Eaton Hydraulics Operations USA, Eden Prairie, MN, USA
7. Document on: ‘ENGINEERING INFORMATION - flow data flow factor and orifice size’
ASCO Numatics, France.
8. Powerpoint presentation for ‘Fluid Power’ by James R. Daines, The Goodheart-Willcox Co.
Inc, Illinois, USA.
9. Technical Principles of Valves, OMEGA ENGINEERING, Inc., USA.
10. Vocational Training Course, HYDRAULICS – 21 Exercises with Instructions, published by
10.
Bundesinstitut fur Berufsbildungsforschung, Berlin, 1973.


Chapter 11 Flow Control Valves and Circuits

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Chapter 11 Flow Control Valves and Circuits

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Chapter 11 Flow Control Valves and Circuits

Differentiate the non-compensated and compensated flow control valves.

Concept of Flow Division

Types of Flow Control Valves

Typical Applications of Throttle Valves

Figure 11.4 | Cross-sectional views of fixed orifice valves.

SG = Specific gravity of the fluid (for mineral oil = 0.85 – 0.9)

Flow rate, Q = 1.41 x C x A x (P/SG)

Figure 11.5 | A cross-sectional view of a throttle valve, fixed-type.

Adjustable Throttle Valve, Pressure-dependent

Figure 11.6 | A cross-sectional view of an adjustable throttle valve, pressure-dependent.

Compensated Flow Controls Valves

Figure 11.7 | A schematic view of a pressure-compensated flow control valve.

Flow Rate through Throttle Valves

In the English units,

Capacity coefficient, Kv = Q/(P/SG)= 114 /(400/0.9)= 5.4 lpm/kPa

[Capacity coefficient, Cv = Q/(P/SG)= 30 /(58/0.9) = 3.74 gpm/psi]

Test Your Knowledge #11.1

One-way Flow control Valve

Speed Control of a Cylinder using a One-way Flow Control Valve

Figure 11.12 | Symbolic representations of many variants of flow control valves.

Figure 11.13 | Two critical positions of a regenerative hydraulic circuit.

Rod_side area, Aret =Aext- Arod

=(20.26 – 10.13) = 10.13 cm2

=0.000246/10.13x10-4 = 0.24 m/s

=0.000246 / (10.13) = 0.24 m/s

Load carrying capacity, forward stroke = PxArod

Load carrying capacity, return stroke =PxAret

Hydraulic Motor Speed Control Circuits

Rotary Flow Divider (or Combiner):

Sliding-Spool Flow Divider: A sliding-spool type flow divider is a form of pressure-compensated

Basic Priority Valve:

Figure 11.16 | A schematic diagram of a basic priority valve.

Figure 11.17 | A cross-sectional view of the priority valve with relief.

Test Your Knowledge #11.2

Objective Type Questions

3. Which of the following is the correct statement?

Figure 11.20 | Question 6

8. Identify the symbol in Figure 11.21:

Figure 11.21 | Question 8

the flow through the valve is doubled? {Ans: Ans: 300%}

Hydraulic Cartridge Systems, USA.

Bundesinstitut fur Berufsbildungsforschung, Berlin, 1973.

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