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Industrial Fluid Power (Hydraulics and Pneumatics) Part 2

Presentation · October 2022

DOI: 10.13140/RG.2.2.26702.13122

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Abhishek D. Patange
College of Engineering, Pune
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Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

Hydraulic circuits

Hydraulic circuits incorporating unloading valve

Unloading valves are pressure-control devices that are used to dump excess fluid to the tank
at little or no pressure. A common application is in high-low pump circuits where two pumps
move an actuator at a high speed and low pressure. The circuit then shifts to a single pump
providing a high pressure to perform work. Another application is sending excess flow from
the cap end of an oversize-rod cylinder to the tank as the cylinder retracts. This makes it
possible to use a smaller, less-expensive directional control valve while keeping pressure
drop low.
How the unloading valve different from a pressure relief valve?
 The symbol for an unloading valve is similar to the symbol for a relief valve except
that the pilot line is not connected to sense pressure at the valve inlet.
 Unloading valves are pressure-control devices that are used to unload excess fluid to
tank at little or no pressure. Remote pilot signal is used to control.
 As in pressure relief valve, pilot from system pressure controls the relief valve.
 Unloading valves are pressure-control devices that are used to unload excess fluid to
tank at little or no pressure. Remote pilot signal is used to control. As in pressure
relief valve, pilot from system pressure controls the relief valve.

A circuit with an unloading valve

 Figure 1 shows a hydraulic circuit to unload a pump using an unloading valve.
 When the cylinder reaches the end of its extension stroke, the pressure of oil rises
because the check valve keeps the high-pressure oil.
 Due to high-pressure oil in the pilot line of the unloading valve, it opens and unloads
the pump pressure to the tank.
 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.
 When this happens, the unloading valve unloads the pump due to high-pressure oil.
 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.

Page 1 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

Figure 1: A circuit with an unloading valve & symbol

Table 1: Working of circuit in figure 1
Envelope I
P is connected to A.
B is connected to T.
Extension of cylinder will
happen.
The unloading valve opens
when cylinder reaches to the
end of extension stroke
because the check valve
Envelope II
All ports are blocked.
Cylinder will not move.
The pump is unloaded to
tank using unloading valve
Envelope III
P is connected to B.
A is connected to T.
Retraction of cylinder will
happen.
When DCV is shifted to
retract the cylinder in III
position, the motion of piston
reduces the pressure in pilot

Page 2 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

keeps high pressure oil in line of unloading valve. This

pilot line of the unloading resets the unloading valve
valve. until cylinder is fully
retracted, at which point the
unloading valve unloads the
pump.
Conclusion: The unloading valve unloads the pump at End of extension, End of retraction,
Central position of DCV. (Pressure in these lines increases after completion of each stroke)

Two-pump hydraulic circuit incorporating unloading valve

 A Hydraulic circuit consists of pumps used to create the flow of oil which is the carrier
fluid. These are positive displacement pumps, mostly piston pumps with swash
plates. So closing the delivery valve or the p line will result in a catastrophic failure.
 An unloading valve is used with two pumps. One creates a high discharge/flow and
the other one able to create a high line pressure with a low oil discharge. Suppose
you want to lift a load using a vertical hydraulic cylinder.
 The hydraulic cylinder rod will move up at a low pressure until it touches the load to
be lifted. After this, the pressure in the system increases. Now, at this high pressure,
we require enough flow of oil into the cylinder to lift the load.
 However, while the system operates without load, it requires only low fluid flow. The
entity that facilitates the occasional use of the high discharge hydraulic pump is the
unloading valve.
 An unloading valve will always divert the flow from the low pressure high discharge
pump into the tank. Only when the pressure of the system reaches beyond a
particular value, the valve is opened and the oil flows into the circuit for the desired
purpose, like lifting a load here.
Sheet metal punching
Two major operations involved in above circuit are
1. Rapid extension of hydraulic ram towards work piece
Hydraulic ram (cylinder) must extend rapidly over a great distance with very low
pressure and high flow rate requirement. Here this operation occurs under no load
condition. (As punching tool connected to cylinder approaches to sheet metal strip to
be punched or work piece)
2. Punching operation
Now hydraulic ram must extend over small distance for actual punching operation
where pressure requirement is high due to punching load and requires low flow rate.
When punching operation begins the increased pressure opens unloading valve to unload
the low pressure pump. Here high flow, low pressure pump will not deliver flow to extending
cylinder when high pressure exists in high pressure line due to punching operation. The

Page 3 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

purpose of relief valve is to protect the high pressure pump from overpressure at the end of
stroke and when DCV is at central position. The check valve protects the low pressure pump
from high pressure.

Figure 2: Two pump and unloading valve circuit

Table 2: Working of circuit in figure number 2
Envelope I Envelope II Envelope III
P is connected to A. All ports are P is connected to B.
B is connected to T. blocked. A is connected to T.
For rapid extension of cylinder, high flow pump Cylinder will Retraction of cylinder
opens and which will do rapid extension of not move. will happen.
cylinder.
(High flow, low pressure)
After completing of extension the valve is to be The pump is
shifted to central position for clamping the punch. unloaded to
Hence till that pump is unloaded to tank using tank using
PRV. PRV.
Now to perform punching operation we need high
pressure and low flow. Hence for punching
cylinder must extend further. Hence we actuate
valve in I position again. When punching
operation begins the increased pressure opens
unloading valve to unload the low pressure

Page 4 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

pump. Here high flow, low pressure pump will not

deliver flow to extending cylinder when high
pressure exists in high pressure line due to
punching operation.

What is the advantage of using an unloading circuit, when feed and speed of a machine
need to be varied?
 When high speed is required during air cutting, high flow pump can be used to get
the rapid extension and cutting time is saved.
 When cutting is taking place ( torque requirement is high), low flow pump can be
used
 This circuit eliminates the necessity of having a very expensive high pressure, high
flow pump.

Synchronization circuit

Page 5 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

Hydraulic circuit with Sequence valve (Hydraulic cylinder sequencing circuit)

Sequence valves control the sequence of operation between two branches in a circuit; that is,
they enable one unit to automatically set another unit into motion. It is used to assure priority
hydraulic pressure in one system before another can operate. An important feature of all
pressure sequence valves is a separate drain connection from the spring chamber. A sequence
valve is different from a relief valve in that the spring chamber is vented directly to
atmosphere instead of to the outlet port on the valve. This allows full pressure to appear on
both cylinders when they stall, instead of the pressure having to divide between them. The
valves sense a change in pressure in a system and transmit a hydraulic signal when the set
pressure has been reached. The valve may be normally open or normally closed, changing
state when the system reaches the set pressure. They may be used to assure priority hydraulic
pressure in one system before another can operate.
Applications: Clamping and machining work piece of any operation in sequence.

Page 6 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

Use of sequence valve in hydraulic circuit:

Figure: Use of sequence valve in hydraulic circuit

Envelope I
P is connected to A.
B is connected to T.
Extension of cylinder 1 will
happen.
Pressure in A line increases
as extension of cylinder 1
completes.
Hence sequence valve 2 will
get open due to increased
pressure.
Extension of cylinder 2 will
happen.
Envelope II
All ports are blocked.
Both the cylinders will not
move.
Both are hydraulically
locked.
Envelope III
P is connected to B.
A is connected to T.
Retraction of cylinder 2 will
happen.
Pressure in B line increases
as retraction of cylinder 2
completes.
Hence sequence valve 1 will
get open due to increased
pressure.
Retraction of cylinder 1 will
happen.

An important feature of all pressure sequence valves is a separate drain connection from the
spring chamber. This is because, unlike a conventional relief valve, a high pressure can occur
in the output port during the normal course of operation. Should it be internally drained, any
pressure in the output port will be reflected back into the spring chamber causing a

Page 7 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

malfunction. In fact a sequence valve may be used as a relief valve in any circuit here
excessive back pressures are encountered in the return line. The independently drained pilot
makes sequence valves insensitive to downstream back pressure.

Automatic cylinder reciprocation circuit

Page 8 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

Hydraulic motor braking circuit

Two hand safety circuit

Page 9 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

Industrial Fluid Power (Hydraulics and Pneumatics) UG: Mechanical Engineering

Page 10 of 10 by Dr. Abhishek D. Patange at College of Engineering, Pune

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