ELECTRO –

PROPORTIONAL
VALVES

1
 HYDRAULIC CONTROL TECHNOLOGY

Servo valve New Series

Proportional valves

Closed Loop
Performance

Hybrid series Proportional

Increasing

Open Loop
Proportional Valves Proportional

Conventional
Valves

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 COMPARISON BETWEEN
CONVENTIONAL AND PROPORTIONAL VALVES

SL.
No. Description Conventional Proportional
1 Setting Mechanical Electrical
2 Stage Control Single Multiple
3 Slope Control In Steps Smooth Slope
4 Circuit Complex Simple
5 Size of Blocks, Pipes Large Small
6 Power Saving Circuit Complicated Simple
7 Feedback Not Available Available

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 DEVELOPMENT OF
ELECTRO - PROPORTIONAL VALVES

Year 1965 ~ 1970 1975 ~ 1980 1980 ~ 1985 1990 ~

Pressure Combination Power EH- Series

Control of Pressure Matching
Pressure &
& Systems.
& Flow ,
FlowControl
Directional & Directional &
Flow Valves
Flow Control Flow Control
Control
Valves Valves.
Valves
Power
Matching
Systems

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 SALIENT FEATURES OF
ELECTRO PROPORTIONAL VALVES
Basic Just Like
Conventional Simple High
Structure
Valve Reliability

Wet Longer Easy to Use

Solenoid Service
Armature
Life Easy to
Type
Maintain

Directly High
Operated Powerful Resistance
Type Driving Against
Contamination

With Current
Amplifier Feedback Function, Stable Control
Dither
 DEVICES FOR THE PROPORTIONAL CONTROL
Indication
Feedback signal in
Power Closed Loop Circuit
Setting Device Amplifier Prop. Valve Sensor

Manual DC input Pilot Relief Valve The Sensor

Dialing type Relief Valves detects the
Relieving & Controlled
DC input
Program Reducing valves Pressure,
with
Control Flow control Flow Rate
feedback
(& check) valves and Speed
Computer type
Throttle Valves etc., and
Control Slow up – Power Saving converts it
down. Valves to electric
Direction & Flow signal.
DC VOLTAGE DC CURRENT control Valves

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 SIGNAL SEQUENCE

Control Power Hydraulic

Supply Power Supply

Control Panel
0~10V
Command Amplifier Prop.
Actuator
Signal Valve

Sensor

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 PRINCIPLE OF OPERATION
Plunger Coil

Spring Force

Magnetic Force

D C Current

( Schematic Diagram of Solenoid )

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 PRINCIPLE OF SOLENOID OPERATION

ELECTRO MAGNET

PERMANENT MAGNET

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 PRINCIPLE OF BASIC SOLENOID OPERATION

NO ELECTRIC
CURRENT
PLUNGER
COIL

Magnetic Field created

ELECTRIC which must travel
CURRENT through air.

1.) Attracts Plunger to an

ELECTRIC equilibrium position.
CURRENT
2.) Creates an output force.
3.) so that magnetic field can
pass 100% through the iron.
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 COMPARISON : FORCE V/S STROKE
Force Conventional Proportional

Force
Stroke Stroke

100 % 100 %
70 % 70 %
Force

30 % 50 %
Force

30 %

Stroke Stroke
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 COMPARISON : FORCE V/S STROKE
Conventional Proportional
Spring Curve

Spring Curve
100 %

70 %

100 % 50 %
Force

Force
70 %
30 %
30 %

Stroke Stroke

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 COMPARISON OF SOLENOID CONSTRUCTION
Air Gap COIL
CONVENTIONAL
SOLENOID

ARMATURE

Air Gap COIL

PROPORTIONAL
SOLENOID

ARMATURE

1
3
 CONSTRUCTION DETAILS OF PROP. SOLENOID

Manual Adj. Iron Core

Screw

Air Vent Coil Bearing

Spring

Air Gap
Plunger

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 PROPORTIONAL HYDRAULIC CONTROL - RANGE
Maximum Flow
Maximum
Operating
Valve Type Pressure
Kgf/Cm2 1 2 3 5 10 20 30 50 100 200 300 500
L /min
1000

Pilot Relief Valves 245

Relief Valves 245 03 06 10
EH Series

Reducing & Relieving Valves 245 06 10

Flow Control (& Check)Valves 245 03 06

Flow Control & Relief Valves 245 03 06 10

Directional & Flow Cont.Valves 245 01 03

High Response Type
Directional & Flow Cont.Valves 157 04 06

Pilot Relief Valves 245

Relief Valves 245 EBG 03 06 10

Reducing & Relieving Valves 245 06 10

206 W 02 03 06 10
E Series

Flow Control (& Check)Valves

245 W 03 06
W W 03 06 10

Flow Control & Relief Valves 245 W W 03 06 10

03 06

Directional & Flow Cont.Valves 245 03 04 06

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 STEP RESPONSE
STEP SIGNAL 0 ~ 100 %
Fig. Shows the Valve requires
100
80 ms to go from 0 to 100% Stroke and
70 ms to fully close.
STROKE %

50
i.e., 150 ms is required to complete one cycle.
150 ms - 1 Cycle
1000ms ( 1 Sec ) - ? Cycles
0 1000 X 1 = 6.6 Cycles / Sec ( Or 6.6 Hz )
80 0 70
TIME ( ms ) 150
STEP SIGNAL 25 ~ 100 % STEP SIGNAL 10 ~ 90 %

100
90
75
STROKE %

STROKE % 50

25

0
0 50 0 40 70 0 60
TIME ( ms ) TIME ( ms )
STEP RESPONSE : A RESPONSE MADE WHEN THE INPUT SIGNAL
SUDDENLY CHANGES FROM A GIVEN VALUE TO ANOTHER GIVEN VALUE
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 FREQUENCY RESPONSE

– Frequency
•Is the number of times any
action occurs in a given
measure of time.
Unit is Hz (Cycles per Second)

– Amplitude Response ( Gain )

•Is a ratio of output change to
input change.
Measured in dB (Decibels)

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 PHASE LAG
– The time required for the output to recreate
the input command. Measured in Degrees.
Cyclic Input
Cyclic Out put

Phase Lag in Time

Degrees
90° Phase Lag
90°

Phase Lag in Time

Degrees
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 PROPORTIONAL ELECTRO – HYDRAULIC
PILOT RELIEF VALVE
 FREQUENCY RESPONSE
Frequency ( Hz)
0.1 0.2 0.4 0.7 1 2 4 7 10 20 40 70
0
- 20 -10
- 40 -20
Gain
Phase ( deg.)

- 60 -30
- 80
Gain ( dB)

-100
-120
Phase
-140
-160
-180

Flow Rate : 2 L / min

Pressure : 80 ± 16 Kgf / Cm2
Trapped Oil Volume : 30 cm 3
Viscocity : 30 cSt

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 HYSTERESIS
Hysterisis Hysteresis
without Dither with Dither
200 200
180 180
160 160
Pressure Kgf / Cm2

Pressure Kgf / Cm2

140 140
120 120
100 100
80 80
60 60
40 40
20 20

0 200 400 600 800 0 200 400 600 800

Current ( mA ) Current ( mA )
Dead Band Dead Band

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 PROPORTIONAL ELECTRO – HYDRAULIC
PILOT RELIEF VALVE
PLUNGER With
COIL Safety Valve
SPRING

PLUNGER POPPET
SEAT SPRING
AIR VENT

Pr. Adj.
MANUAL PR.
Screw for
ADJ. SCREW IRON CORE Safety valve
TANK PRESSURE
PORT PORT

Without
Safety Valve
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 PROPORTIONAL ELECTRO – HYDRAULIC
PILOT RELIEF VALVE
 STEP RESPONSE
Flow Rate : 2 L / min
Kgf / Cm2 Trapped Oil : 40 cm3
90 Volume
Viscocity : 30 cSt

70
Pressure

50
0.2 Sec

30
Step Signal

10
Time
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 PROPORTIONAL ELECTRO – HYDRAULIC
PILOT RELIEF VALVE
FLOW RATE VS PRESSURE
Viscosity : 30 cSt
A
250
235
220
B
Pressure Kgf / Cm2

160
145
130
C
70
55
40

0 1 2 L / min
Flow Rate

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 PROPORTIONAL ELECTRO – HYDRAULIC
PILOT RELIEF VALVE
 FREQUENCY RESPONSE
Frequency ( Hz)
0.1 0.2 0.4 0.7 1 2 4 7 10 20 40 70
0
- 20 -10
- 40 -20
Gain
Phase ( deg.)

- 60 -30
- 80
Gain ( dB)

-100
-120
Phase
-140
-160
-180

Flow Rate : 2 L / min

Pressure : 80 ± 16 Kgf / Cm2
Trapped Oil Volume : 30 cm 3
Viscocity : 30 cSt

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 PROPORTIONAL ELECTRO – HYDRAULIC
PILOT RELIEF VALVE
 CONTROL PRESSURE VS INPUT CURRENT
250

A
200
Pressure Kgf / Cm2

150

100 B

50

C
0
0 200 400 600 800 1000
Input Current mA
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 PROPORTIONAL ELECTRO – HYDRAULIC
RELIEF VALVE
PROPORTIONAL
PILOT RELIEF
AIR VENT VALVE WITH
SAFETY VALVE

MANUAL PR. SLEEVE SEAT

ADJ. SCREW
SPRING

POPPET Graphic Symbol

VENT PORT PR. PORT TANK PORT

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 PROPORTIONAL ELECTRO – HYDRAULIC
RELIEF VALVE
 STEP RESPONSE
Kgf/Cm2

200

Pressure 160

120 0.2s

80 Step Signal

40
Time
Flow Rate : 200 L / min )
Loading : 1 ltr.
Volume
Viscocity : 30 cSt
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 COMPARISON OF CONVENTIONAL &
PROPORTIONAL PRESSURE CIRCUIT
Conventional Circuit Proportional Circuit
Switch ON Sol. a – d to get Only One Valve is required
4 different pressures ., By changing the Input
Current, the Pressure can
be changed.

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 PROPORTIONAL ELECTRO – HYDRAULIC
FLOW CONTROL VALVE
40W Series PR. COMPENSATOR PISTON
( Direct Type )

INLET PORT

DRAIN PORT
Graphic
Symbol

OUTLET PORT
O
M SPOOL ORIFICE SLEEVE
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 STEP RESPONSE

40 Ohm 10 Ohm

L / min L / min
140 125 L / min 150 125 L / min
120 125
100 100

Flow Rate
60 L / min
Flow Rate

80 60 L / min
75
60
50 0.2s
40 0.2s
25
20 Step Signal
Step Signal
0 0

Time Time

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 FREQUENCY RESPONSE

40 Ohm
Frequency ( Hz )
0.1 0.2 0.7 1 2 4 7 10 30
0 0
- 20 - 10
- 40 - 20
- 60 Gain
Phase (deg. )

Gain ( dB )

- 80
- 100 Phase
- 120
- 140
- 160
- 180
Input Current : 460 ± 70 mA

Pressure : 70 Kgf / Cm2

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 COMPARISON OF CONVENTIONAL &
PROPORTIONAL FLOW CIRCUITS
Forward Backward Forward Backward

Sol. 1 Sol. 2 Sol. 1 Sol. 2

Intermediate
Speed
EFG-* -
Signal
Sol. 3 Sol. 4
PUMP PUMP

Low High
Speed Speed

Conventional Proportional
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 LOAD SENSING -
COMPARISON OF HEAT GENERATION

HEAT GENERATED
= P x Q x 860 Kcal / Hr
612
= 40 x 40 x 860
612
= 2248 Kcal / Hr

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 LOAD SENSING -
COMPARISON OF HEAT GENERATION
VENT
LINE

Set
Increase pressure At
100
P Bar

REMOTE CONTROL
RELIEF VALVE

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 LOAD SENSING -
COMPARISON OF HEAT GENERATION

w Load Pr. + 5 Kgf/Cm2

(10 + 5 = 15 Kfg/Cm2 )
Load Pressure = 10 Kgf / Cm2

Flow Control
Valve Set
At
P 100
Bar

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 LOAD SENSING -
COMPARISON OF HEAT GENERATION

HEAT GENERATED
= P x Q x 860 Kcal / Hr
612
= 40 x 15 x 860
612
= 843 Kcal / Hr

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 CONVENTIONAL POWER SAVING VALVE
FLOW CONTROL
VALVE

RELIEF VALVE

TANK DRAIN
INLET PORT OUTLET PORT
PORT PORT
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 PROPORTIONAL ELECTRO – HYDRAULIC
RELIEF & FLOW CONTROL VALVE
40W - 10W Series FLOW CONTROL
SOLENOID

PROPORTIONAL
PILOT RELIEF
VALVE WITH
SAFETY VALVE

TANK DRAIN
INLET PORT OUTLET PORT
PORT PORT
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 POWER SAVING CIRCUIT
Conventional Proportional Circuit
Circuit Energy Saving
Energy Saving Energy Saving
Q Q Q Q
Power
loss Power Power Power
loss loss loss

P P P P

• Flow Matching • Load Sensing

Circuit Circuit
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 PROPORTIONAL ELECTRO – HYDRAULIC
DIRECTIONAL AND FLOW CONTROL VALVE

Max. Op. Pr. : 250 Kgf / Cm2

Max. Flow : 01  30 L/ min
03  60 L/ min

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 PROPORTIONAL ELECTRO – HYDRAULIC
DIRECTIONAL AND FLOW CONTROL VALVE
INPUT CURRENT V/S FLOW

L/ min
120

100 AB A B

80 P T P T
Flow Rate

60

40

20

0
1000 800 600 400 200 0 200 400 600 800 1000
Input Current mA

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 PROPORTIONAL ELECTRO – HYDRAULIC
DIRECTIONAL AND FLOW CONTROL VALVE
 PRESSURE DIFFERENCE V/S FLOW
L /min
140 A B
120 750 mA
P T
700 mA

Flow Rate
80

Valve Pres. Diff. 40

Kgf / Cm2 245 210 140 70 600 mA

70 140 210 245 Kgf / Cm2

600 mA
40 Valve Pres. Diff.
Flow Rate

80
A B
700 mA
120
P T 750 mA L / min
140
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 LINEAR VARIABLE DIFFERENTIAL TRANSFORMER
INPUT ( LVDT )

SECONDARY PRIMARY SECONDARY

COIL COIL COIL MOVEMENT

IRON CORE

OUTPUT

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 HYBRID SERIES PROPORTIONAL VALVES

24 V DC Power
Supply Pressure display panel (option)

Power Amplifier
Command
Signal
Voltage Pressure Sensor
Input Incorporated

Voltage
Output for
Pr. monitor

Alarm Signal
Output
Proportional Electro Hydraulic Relief Valve
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 INSTALLATION REQUIREMENT
Air Vent
Air Vent
GOOD EXAMPLE

SOL
Air Vent

SOL
SOL

Air Vent

SOL

BAD EXAMPLE
SOL

SOL

Air Vent Air Vent

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 TYPICAL APPLICATIONS

ELEVATORS
ROLLING MILLS
PLANERS
INJECTION MOULDING MACHINES
PRESSES
SURFACE GRINDING MACHINES

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Proportional Direction and Flow Control Valve
with LVDT

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