Assignment No.

3
UNIT – 3 CONTROL VALVES

1) Explain with sketch working of pilot operated pressure relief valve. How it is different from direct acting type?
Pilot operated pressure relief valve as shown in figure

Working: It is simplest type valve contains a poppet held in a seat against the spring force as shown in figure. It
consists of two ports and one of which is connected to the pump and another is connected to the tank. The fluid
enters from the opposite side of the poppet. When the system pressure exceeds the present value, the poppet
lifts and the fluid is escaped through the orifice to the storage tank directly. It reduces the system pressure and
as the pressure reduces to the set limit again the valve closes. Different from direct acting type: Direct-Operated
Regulators respond directly to variations in downstream pressure to provide the necessary flow and pressure to
satisfy the system set point. Outlet pressure opposes the balance force provided by the spring to determine the
plug position. Therefore, for direct-operated regulators, Outlet pressure is also considered the loading force. Pilot-
Operated Regulators consist of the same essential components of direct-operated units (plug and seat,
diaphragm, spring) with the addition of a pilot which separates Outlet pressure and the diaphragm loading force.
The pilot requires an external sense line connected to the downstream piping. Measuring pressure further
downstream of the valves allows for more accurate sensing of the true outlet pressure conditions as it moves the
sense point away from the flow turbulence generated by the plug and seat. The pilot valve can simply and
effectively be considered a second regulator, providing additional control to the main regulator, improving overall
sensitivity and, ultimately, accuracy.
2) State the meaning of pressure compensation in flow control valve. Draw a sketch of pressure compensated
flow control valve and explain its working.
In any hydraulic circuit there are slight variations in presence of oil. When pressure changes the rate of flow
changes but many circuits require constant flow regardless of input or output pressure variations in the circuit
then the pressure compensated flow control valve is used.

a.
 It consists of hollow cylinder shaped poppet at the bottom of which there is a fixed orifice. There is a spring inside
a poppet as shown in fig. Pressurized oil entering through the inlet port will apply full force on the bottom of the
poppet and will try to compress the spring by shifting the poppet to right the poppet will move to right and will
close the outlet port. Then movement of the poppet toward right will stop. Now flow of oil through the orifice
will start. Oil will occupy the bore of cylinder this flow of oil will equalize the pressure on both ends of the poppet.
The poppet will then balance. During the process of poppet balancing, spring will expand and poppet will move
toward left thereby uncovering the outlet port. A balance will automatically be established between quantity of
oil through orifice and quantity of oil going out through the outlet port even if the pressure of incoming oil
changes, the rebalancing will establish automatically and constant flow of oil will come out.
3) Explain with sketch working of 4/3 rotary spool DC valve.

The rotary spool directional control valve has a round core with one or more passages or recesses in it. The core
(rotor) is mounted within a stationary sleeve (casing). As the core is rotated within the stationary sleeve, the
passages or recesses connect or block the ports in the sleeve. The ports in the sleeve are connected to the
appropriate lines of the fluid system.
4) Explain why 4/2 DCV is preferred for hydraulic & 5/2 DCV for pneumatic systems.
4/2 DCV for Hydraulic system and 5/2 DCV for pneumatic system.

4/2 DCV in hydraulic system and 5/2 DCV in pneumatic system because of following difference
4/2 DCV in hydraulic system 5/2 DCV in pneumatic system

In hydraulic system, in four-way 4/2 Most 5/2-way valves have a movable

DCVs, two flows of the fluids are
controlled at the same time.
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spool with seals along the length in a
cylinder. By moving the spool through
the cylinder, the valve ports are
connected or blocked. Also the valve can
be direct operated or pilot operated. With
direct operation, the actuator is directly
connected to the spool.
They are quick to operate because of
small switching movement.
In pneumatic system, the 4-way spool
valve can be controlled by using two
operators, one on each end or by a spring
return and a single operator( 5/2). The
flow path when actuated at the 14 end of
the valve is from port 1 to port 4 and
from port 2 to port 3. Port 5 is blocked.
When the valve is actuated from the 1 2
end, the flow path is from port 1 to port
2 and from port 4 to port 5. Port 3 is
blocked. Each cylinder port has a
separate exhaust port.
5) State different types of pressure control valves with their applications.

S Pressure control valves Applications

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N
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1 Pressure relief valves Relief valve opens and bypasses fluid when pressure
exceeds its setting.

These are used mostly in all circuits.

2 Pressure-Reducing This type of valve (which is normally open) is

Valve used to maintain reduced pressures in specified
locations of hydraulic systems.

3 Unloading Valves high-low pump circuits where two pumps move

An actuator at a high speed and low pressure,
punching press,

4 Counter balance valves They are used to prevent a load

from
accelerating uncontrollably. This situation can
occur in vertical cylinders in which the load is a
weight. This can damage the load or even the
cylinder itself when the load is stopped quickly
at the end of the travel.

6) Describe with neat sketch pressure & temp. compensated flow control valve.

Pressure and temperature compensated flow control valve

Schematic diagram of a pressure and temperature compensated flow-control valve is shown in Fig.
Its operation is essentially same as the restrictor type, pressure compensated flow control valve in association with
a throttle type temperature compensating device. In the compensatory spool, the pressure is sensed to the bottom
of the spool through a passage drilled in its body, instead of having a separate sensing passage. In order to attain
balance position, the compensatory spool moves and adjusts the area of metering orifice. This gives necessary
pressure compensation.
Also instead of using the usual throttling arrangement, a cup shaped device with “V” notches is used for better
control on flow rate. This cup is held by a small spring against the shoulder of an aluminum aloyrod which extends
through the cup into the oil flow. It is set for a particular flow rate. As temperature of oil rises, the oil becomes a
little thinner and tend to flow faster through. However, the increased temperature also causes the Aluminum rod
to expand and close the throttle opening to compensate for the change in oil viscosity. Thus even with the thinner
oil, the flow rate stays essentially the same.
A check valve is frequently incorporated to allow relatively unrestricted reverse flow.
7) Sketch the two positions of rotary spool type 3/2 DCV & explain in brief.

A rotary spool valve consists of a rotating spool which aligns with ports in stationary valve casing, sothat fluid is
directed to required port. Pressure port (P), Actuator port (A) and Receiver port (R) are the ports in casing. The
port „P‟ is a pressure port though which pressurized fluid is coming in the valve. „R‟ port is the port through which
used fluid is returning to the Receiver.

From fig (a) which indicate first position of the rotary spool type 3/2 DCV connects port P to port A While receiver
port R remains closed. In second position shown infig (b) of rotary spool type 3/2 DCV port A is connected to
port R while port P remained closed.

8) Explain shuttle valve with neat sketch.

Shuttle valve: A shuttle vale also known as a double check valve/ OR gate, allows pressure in a line to be obtained
from alternative sources. It is primarily a pneumatic device and is rarely found in hydraulic circuits.
Construction is very simple and consists of a ball inside a cylinder. If pressure is applied to port X, the ball is
blown to the right blocking port Y and linking ports X and A. Similarly, pressure to port Y alone connects port Y
and A blocks port X

9) Explain sequence valve with neat sketch.

Sequence valve
A primary function of sequence valve is to direct flow to different components of the circuit in a
predetermined sequence. It is a pressure actuated valve which senses a certain change in pressure from
the set value. It then takes the actions to direct the fluid in a definite predetermined order. It also maintains
the requisite minimum pressure in the primary line while the secondary operations occur.
Figure shows operating principle of a direct acting, normally closed sequence valve. In this position, fluid
passes through the valve from the inlet port P to primary outlet port A at system pressure. When the first
step in the sequence is completed, the system pressure increases to act against the exposed area of the
piston. Continued increase in pressure causes the piston to compress the spring and unseat the valve,
thereby directing the flow of fluid at high pressure through secondary outlet port B. Fluid pressure is
maintained in both branches of the circuit so long as the sequence valve is open. Adjustment of the
sequence valve is accomplished by compressing or extending the piston with the cap screw.
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10) Draw and explain working of pressure reducing valve.

The main function of pressure reducing valve is to reduce the pressure in particular branch of the circuit to different
level as demanded by consumer in that branch. Construction: It consists of spool and spring housed in the bore of
valve body. Spring compression can be adjusted by pressure setting screw. Port P is pressure port connected to
pump. Port A is consumer port requiring reduced pressure. Working: As shown in normal position, port P is
supplying oil to consumer port A. If the main supply is below the set pressure, there will be continuous flow from
P to A. Hence normally this valve is open. When outlet pressure rises to valve setting then oil will flow through
‘passage x’ and will act on spool and spool will shift to right thereby partly closing the port A. Now only enough
flow will pass through port ‘A’ so that consumer connected to A will receive reduced pressure.

11) Explain 4-way-3 position direction control valve used in hydraulic system.
4-way-3 position direction control valve used in hydraulic system is known as 4X3 DC Valve. The valve has four
ports and three positions. Following figure shows the Normal and working positions of DCV. Spool of this valve
is having three positions. The spool is so selected because we have to obtain third position also called as ‘Closed
Centre Position’ This position is shown in figure. We have shifted the spool in such a manner that all ports are
closed to each other. Mo flow from port P to port A or B and no flow from port A and B to R. When DC valve
attains this position, pressured oil returns to reservoir via pressure relief valve. The closed center position of DC
valve is suitable for immediate closing of movement of actuator.
Position- I

a.
Position- II
 b.
Closed center position

c.
12) State any two applications of 3 × 2 DC valve. Draw symbol for the same.
Applications of 3 X 2 DCV:
 To start, stop and change the direction of motion of a Single acting cylinder. (Clamping of Job)
 To actuate Pilot control of 5/2 DCV
 To isolate certain branch of a circuit.

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