6.

9 CALCULATION OF FLOW QUANTITY THROUGH AN ORIFICE Where Qo = flow through an orifice,A0 =area of cross-section of orifice,m2,= flow resistance factor,p =oil density kgf/m-4s2 An useful method of calculating the area of the orifice required. Where A0=area of orifice in mm Q =flow rate in l/s P =differential pressure in bar. One must keep in mind that the diameter of these orifices is usually small and often it is essential to provide for filtration on the up-stream side. Conditions are worse for a needle valve where the orifice takes the from of an annular restriction which may be opened only a fraction of a millimeter and can be readily obstructed. Obstruction due to silting often occurs in restrictors which are used to damp out pulsations in the flow to a pressure gauge. For precise speed control a pressure compensated flow control valve is to be used. A valve of this type maintains an almost constant pressure drop across a fixed orifice to produce a constant flow rate. For this purpose it incorporates an internal regulating system comprising of a variable orifice, with pressure acting on the ends of a spool against a biasing spring that has a low rate. 6.10 POSITIONING OF A FLOW CONTROL VALVE When the flow from a fixed delivery pump is divided between particular sub-circuits, the problem of correct apportionment of flow to the orifice arises. There are 3 primary positions for the flow control valve. 1.meter-in to control. Here metred oil is sent to cylinder. Any excess fluid is forced through the relief valve to return to the tank at the maximum pressure Ps. Since excess flow passes through the relief valve a powerloss Ps equivalent to P multiplied by Qr is encountered to reduce the efficiency. This method is useful for unidirectional opposing loads on rams that are frequently used, or when low power levels are involved. Ps is the system pressure and Qr is the flow rate diverted to the tank from thw relief valve. 2.meter-out-flow. The oil from the actuator is passed through the flow control valve and with this position the loading conditions of all types can be controlled. The maximum design pressure for the ram must be greater than the system pressure as:

P2 =Ps A1/A2 and A1 is greater than A2 resulting in pressure intensification. Once again power loss is encountered given by Ps.Qr. the circuit is useful for loadings of all types, and particularly for infrequent applications at low power. 3.meter-by-pass-often used in machine tools. Here ram speed is effectively by returning some of the operating fluid to the tank through a flow control valve. The remaining flow then determines the speed. The pump is connected directly to the actuator and the power loss is minimised at P1 (QP Q1) where P1 is less than Ps. 6.12 PROPORTIONAL PRESSURE AND FLOW CONTROL VALVES In the recent past, a new range of valve are being developed and used in hydraulic system. Proportional Remote Controlled electro hydraulic pressure and flow controlled valve are such new addition in this respect. The main advantage of these valves is their ability to control the pressure and flow rate proportionately and provide remote function. The variation in pressure and flow is effected by varying the electrical input signal to a proportional solenoid which is used to actuate the valves. The input electrical current is derived from amplifying devices which could be located remotely from the valve. Figure 6.19 shows a simple design of a proportional flow control valve and its principle of operational.

The valve consists of a compensator spool (1) biased against a spring (6). A proportional solenoid (2) is fitted to the valve body such that the solenoid plunger when excited can push the smaller moving spool (4). An important feature of the valve is its ability to determine the neutral position of the smaller moving spoll (4). A manual adjustment screw is provided in the solenoid cap to set the adjustment of the solenoid plunger manually if there is electrical failure and thus the valve can be operated as a conventional one to get the desired fluid flow. For initial flow rate adjustment there is a zero adjustment arrangement