CHAPTER 8

PRESSURE ,'CONTROL

1
, The two 'control factors which affect energy transfer are prcssure and flow, PresslIre control affects the potential energy level uf (he flujJ in the system. Flow cont'rol reglllntes the qllnntity af fluid Pllssing n rcfcrcncc !,oilll !,cr IIl1il nI" lillle. 'I'hc prouuct 01' pressure and flow r,lc is the power transferred by the fluid in the circui!. Two pressure control modes are used in fluid power circuits: 1. direct control of the pressure level, such as: relief valves, to control maximum pressure, 'redllcillg valves, to control pressure at some level be/mil maximum system pressure and, 'pre sSlIre-compellsa {ed vn ria hl e-displnce lIlell { pUl11ps. 2. secondary control, exercised when a given presI surelevel is reached, sllch as: .-:.J.' !fi..L-~---c.'sequellce valves, to swith~ 1~ secondary circuit when fluid pressure in the primary circut has r-eached a preset le vel, a nd .._., ctJU1-~~ '/lloadillg valves, to bypaSs- pllmp llow to reservoir after system pressllre has reached a preset leve!.
v~

FUNDA MENTA L.S

J~' Cd--~./-J tf-p,~~r~~

/V1 jt7~-vC;

Area exposed losyslel11 pressure

1>

Pressure relier valve

Tank

Fig. 8.2. Oirectacting means for controlling

re/ief va/ve is most common/y maximum system pressure.

u~ed

not affected

by changes

in fluid temperature.

DIRECT CONTROL

OF PRESSURE

LEVEL

Control of Maximum Pressure

Inits simplest form, control of maximum fluid pressure can be achieved with an orfice, Figure 8.1. For control to be uniform, this method reqllires constant load resistance, constant temper; atllre, and a ,fixed-displacement rllmp. A sharr
'r."dJ'> ,jPcdged
.~ .)-.v ;-1.1

orficc has the advalltagc lhal il is virtually viscosity insensitive 1, that is, its performance is

Orifices o.ff~r the most economical type of control d:-/Yv'-.hA-/ - and mlIllmum performanceoc'-':'~ .' . ~'jJ / /-? /} l. Direct-acting reHef valves. A relief valve is the most commonly used means to control maximum rressure in a systemo It consists basically of a moving eleinent, such as a poppet, A, which is exrosed to primary circuit pressure, Figure 8020 A hydmlllic force pA, (pressure x area acted upon by the nuid), is opposed by the mechanica/ force cxerted hy l springo When system prcsslIre reaches the preset level,pA overcomes the spring force, the reJief valve unseats and allows_fluid to '><.' v , bypass to tanko The pressure dropucross the val ve is equal to primary system pressure. Note that the relief valve poppet and its sea! form an annlllar orifice. The more the relief valve arens, Ihe grc;lter lhe arca of Ihis annulnr orilicc.o 1;low, (j, through an orifice is expressed by the
equntion2

"'

F/g. 8. {. Sharp edged, fixed orfice pro vides simp/es/ form of max/mum pressure control in a system.

IJlllroduc{ioll {O Fluid Mechaliics, R.W. Henke, AddisonWesley Publishing COo, Reading, MA, 1968, pp. 75-80 47

Q = eA., V (2gt,p )/y characleristic af.lhe whcrc e is a cocfficient orifice, !lo is the orifice area; .p is JI~e pressllre drop across the orifice, expressed in psi;y is sp~cific weight ofthe fluid andg is acceleration dlle to gravityo This expression indicates that flow is a function of the square root of the pressure differential across the valve. As I1p approaches the 2lbid: pr. 76-77

preset pressure,the valve will open partially. Therefore only parl 01' pump Gulpul will pass lhroughthe valvc . . A direct-acting relief valve operales over a pressure band, rather lhan al one specifc presprC'.I'sl/jc,

Ruplure

disc

Hydraulic

fuse

sure. Al some pressure level, c;dleJ Ihe crtlcking ,1 percentage 1IlevalIOlalopCl;-sljghlly lQi.l!hLw tan". In ~}f "" 8.4. Nydrau/ic luse consisls 01 a 'of ve flow to bypass lo a smiill ~ Fig, e l't'cct , il h!I'C'(Ls ...ifF somc ol' Ihe plllllp' s 0111 pllt anel ( bllrsts instan/ly dI a prosol pressure redllces inclow rate lo Lhe circllil by t!liil ilIlHllln 1. .. ,[P ,
G

rupture

disc which

. I lo lall k'" /\( lis Wll Iel' alll I more 11. l' IS ~b' llll '. As level the valve lhe rateaIhe pressure setting, increases, opensvilvc opens J/J pressl/re enough}o bypass all pump outpul lo tank .. Thus lhe relief valve prOlecls circuits and olher componenls in lhe syslem frolll excessi ve pressure. 1'0 properly design a circuil with a relief valve, the designer mustknow lhe cracking charactcristics al' lhe pal'licular valve.' 2; Piloled relief valve. A two-slage relief valve ovcrcomes the disadvantages 01' lhe dirccl-acling relief valve andis called a pilot-operated )!ull'!', Figure 8~3. A small pila/ pis/o/l isheld on ils seat by a relalively long, low graclienl spring, Ilecause lhe pilot piston has a small diameter, the hyJraulic force ading on il is also smal!. 1'his minimizes the cracking effects commonly nOliceable in Jir~cI-\ acting reliet' valves. ' L flJ.c'AJ.fl-JJ-<-/'>'1'he l7laiJi fJoppet is helJ on ils seat by the force exerted by hydraulic pressure tllliJ aCling on Jifferential areas, A and (l. When the pilOI valve apens, some of the fluicl acting on A of the main poppet tlows to tank, A lemporary pressure imbalance iscreated,.lifiing. the main poppet off ils sea!. .This happensso fast that the cracking range of the main,' popp~t is greatly reduceJ. 1'he yiloFoperated' reliel' valve is 1l111chmore . stable Ihan the c1irect-actingtype. In ;Iddilion, il can b':: venlcd remolely lo unloild lhc pllnlp, giv; Illc;lilS lli' Cllsllring ing Ihe circuit designer grealer stabilily amI closer cOlllrol, and provides the addcd versal ilil Y 61" re!llo!c L'lllllm!. 3. HydJ'aulic fuse. The hydraulic fuse, Figure 8.'1, iS-.kiLl lo an elecrric fuse. It consisls ora ruplure disc which blows oul al a presel pressure level,
Pilol valve '.., I symbol

as

iJladdur j) Flexible

/' Oil'll~:~"r,."" '~ .....

Accllmulalor

Unloading

valve '

Fig. Maximum syslem pressure can also be controlled wilh an accumulalo( and an unloading va/ve,

85

h,.ve,))rp~Y"

>;t ,,'
.~--,

J
Simplifed

Fig. 8.3. Pilol operaled. 2-slage re/iel arawaGl<s o( (]'(rccr lcrrng reHer va/ve,

valve overcomes

releasing syslem oi] lo tank. Iris used where the rate ofxessure rise is very high, 150,000 psi/sec for example, and pressure relief must, for al] intents and purposes, be ins/an/aneolls. 1'his rcaction rateis too fast for a conventional relief valve to respond in the necessary time. Like an eleclric fuse, Ihe hydraulic fuse must be replaced, (it cannot he rese!), and Ihe system remains inoperalive unlil Ihe fuse is replaceJ .. 4. Shock SlIl'llI:cssor valvc. This is a spccial valvc dcsigncd lo opcn on ; signal il receives when lhe ~J2;i... rlle ofprcssllre rise reaches u prcscllevel. ollsllOCk Wilves hc!'orc Ihey relch Ihcir mlximum potenlial amplilude. 5. Accllmlllator control. Maximum syslem pressllre can be conlrolled wilh an accumuJalor and an unloading valve, Figure 8.5.' In lhis configuralion, system pressllre is a t'llnction of Ihe gas precharge, and Ihe volume ol' flllid in the accumulator. Maxillllll11 pn:sslIre dcpends on the sctting 01' lhe IInloading val ve. When l presel pressure is rcached, (he 1II110ading valveopens and bypasses pump Olltpllt to'tank. A check valve in lhe line prevenls the accumlllalor from being unloaded al Ihe same lime. 6. Pump control. Pllmp control of maximum pressure involves the IIse of a pressllre-compensated variable displacemenl pllmp, Figure 8.6. Funclionally, a pressure compensator control is a hydrau]ic cylinder which varies the position of the pumping elemenrs, Opposing lhis cylinder is a

48

\.
-- - .-----------

tnle!

,,#;

Itl M.
Comp~nsalor ~~ ~~. Compensalor

spnng ~ ~ plston .1aximum displacemenl Zero displacemenl posilion (deadhead) position variable F;g. 8.6. /n schematic of pressure compensated, dlsp/acement vane pump, s'mall cy/inder a/lers posilion of cam r;ng, thus varying pump disp/acemen't,

pring, Figure 8.6. A compensator spring acting on a cam ring holds the pllmping elements in the maximum displacclllcnt poSiliol1, f'. ;IS shown. When systelll pre'sslIrc reaches :1 presel level, called theclltf~frpressure, lhe force exerled by lhe compensa/or cylinder,exceeds tlJ:1101' lhe spring and s.larts lo shift lhe calll ring lo Ihe len, lowanl neulral position. The higher the pressure, lhe greater the hydraulic force and the farther it shifts he cam ring toward neutral. At some poi nt, called he dead/ead presslIre, the cylinder force is high enoiJgh to shift the cam to fui] neutral position. ThllS, while the rotor and vanes still rotate, no ol is being delivered to the system. , A pressure-compensateu pump can function as a systein relief valve. Because no oil is being throttled across the valve, less energy is lost through heat generation, making lhe pressurecompensated pump more efficienl than a relief . valve. In most cases, it is no( desirable to use a pressllre-compensated pUlllp 11/1(/ a rclief valve in lhe same circuit. becallse 01' hydr,llIlic feedback signals be(ween them., If a relief valve is used, il should be set 200-300 psi highcr Ihan plll1lp deadhead sctting, to avoid inslabilily or Ihe systemo PRESSURE CONTROL IN CIRCUIT BRANCHES 1. Pressurc rcducing valves. This normally-open, 2-way valve senses syslern pressure c/Olt'lIstrCOI/7 from the valve inlel. There are lwo hasic IYres. One rnainlainsfixcc/ rcduccd 11I'eSSlltTin a circuit branch regardless ofthe pressure in lhe balance of lhe system, Figure R.7; the olhcr lIl:linlai]lS a I'xed pressure difTcrcnlial lo providc I'o/'yillg rcduccd pressure with change in system preSSllre, Figure
8.R.
",~'-.l '7 .

Fig. 8.7. Standard design lor control/ing with pressure reducing va/ve.

system

pressure

Like reliefvalves, pressure reducing val ves can be either direct-acting or pilol-operated. The circuit in Figure 8.7 illustrates several design fealures. When cylinder, A, extcncls, fluid pressllre illcylinder A is controlled by syslem relief valve, 49

D. Pluid pressure in cylinder B is controlleu by pressurc reuucing valve, E, within the maximui11 pressurc r:lllge conlrolleo by relief valve D. Ir fluid prcssure in cylindcr B islow, ~then, relief valve, /), contmls overall syslem presslIre: fluid is conlrollcd by relicf pressllre lo c"ylllder valve, /'", on lhe exlend stroke: by relief valve D on retract stroke. If fluid p.ressure in cylilider A drops bclow the setting 01' relief val ve, F, then cylinder will operate al the sarne pressllre as cylinder ;\ . On lhcir relrael strokes, cylinders;\ ami are conlrollcd by relief valve, D; while cylinder II is conlrolled by pressure reuucing vaJve, E. '1'0 cnsure proper fllnctioning, pressure reuucillg v:llves shollld be draincd lo t:lnk. This p'revcnls downslream pressure builuup (backpressllre) dlll' lo Icak:lgc, in norl1l:ll rcturn lines, t\1l11lhcr :lpplic:llion suilablc rol' sOllle types 01' reducing v:llves, is shown in Figure R.R. Here, a rcdllcing valve, (;, supplies a sccondary brand, at a pressure level below that in lhe primary circllil. 2. Sequcllce valves. A sequence valve is a normally-closed (lIsually) internally'piloted valve which remains closed lIntil rressure in the primary circuil reaches the presel pressurc level al'

~---------------------------------

--,-~

Ihc vdve, When this OCCllrs, SC'IIICIlCC,';dvc, 11, Figllre H,9, opens 10 pmvide Olllput Ilnw inlo lhc secolHI<lry circuil. As illllslrled, Ihis Iypc orcoll11'01 rrequenlly uscJ lo switch now lo a sccnndis ary circuil arter lhe aclualor in Ihe primary circuit has reached lhe end 01' ilS strukc allLl prcssure slarts lo rise. This design c1iminltes the nced 1'01' a Ji,:eclional conlrol valve t'o sequence llows. NOle lhal in the circuil in Figure 8.9, seCjllence valve, 11, will close again whcn lhe dircclion;d conlrol valve in 13ranch 1 (not shown) is shi!'ted lo relrae! cylinder A. '1'0 prevenl premllurc nper\lion, design opcraling prcssllJ'c lo cylilldn A in Branch 1 mllsl be he/ol1' the sctting 01'seCjllence valve,11. 3. COlllllcrba/ance va/ve. Figure X.IO illuslralcs a lypical application ora cOllnlerbalance valve,J. It is ;1 llormally-c1oscd, 2-way valvc witll internal pilot, internal drain, ancl (usuillly) a bllill-ill, frecllow check valvc for reverse now. II is useo 10 prevenl free fall of a load helJ IIp by j'cyli'nJer 01' flllid mo(or, 01'lo proviJe conlrolleo resislance in a line. Overcenter valves are counterbalanee val ves wilh external piloting lo aecolllllloJale load reversals on actualors. Brake valves are special cOlJnlerbalance valves used with hydraulic , mOlols,rigu're 8.11. 4. PresslIreswitch. A pressure switch, Figllre 8.12, is iln eleClrical device operaled hy il pressllresellsilive elcmenl sllch as ;\ hOllnll)ll lllhe 01' a hellows. It can cllJale a soklloid-clllllrollcd valve wl1ell il presel prCSSllre is n:;lcllcd. Tllis valve 1I1ighllllllllaJ a plllllP, swili.'1l 10;1 SCL'(llllJry circlIit, 01' reverse an aCl\lalllr. 5. 1'1I1ll(> 1I1lloadillg. Thollgh nol a prcssure cOlllrol lechniljue inlhe strictes( scnse, PU]l1Pullloading is
Inlel

Inlel

To'branch 1 cylinder

--Fig. 8.9. Sequence va/ve contro/s lic circuil branches. fluid pressure

lo brancll
2 cylinder in IJydrau-

1\

( ~ ~liG;
Tank P,lIlI;IIY brlllcl1

1-i9 U. 10. CUII/llul IJydraulic circuil

ba/ill/;U Vil/va conlro/s branch.

fI/litl pressllre

in il

01' CllllSiderhle imporlance in some circuil designs because it reduces power consumption Juring idle periods in lhe cycle.By eliminating the nced to by pass oil over a relief valve, an unloaded pump reduces the amount 01'heat a syslem gener-

a .oressure

Fig. 8.8. Pressure reducing va/ve supplies a secondary branch al

beJOl-v Iha!

01 primary

circuito

}t~ ales. We have aheady discussed the use 01'the unloading valve. Here are some addilional lIseful pressure control techniques. a) COI//ro/-I'II/\'e /I1//oodil1/:. Figure 8.13 shows a circllit using a 2-way, normaJly-closed, direClinn;)1 COn/rol valve, K, whiCh ven/s syslem
50

- 1

relief valve, L, to unload the pump. The solenoid in vaIve, K, is actuated by a limit switch or some other signalling devicc. Note that in this apj1lication, the normally-closed directional control val ves IIlllsl be centered to unload the pump. As illllstratcd in Figure. 8.14, an b) AC('11II111/(/IO,.. accumula'tor maintains a presct system pressure whcn t he' closed-cent el' di rcel ion:" cont rol valve . is in nellt~al. A presslIre switch, M ,.energizes the solenoid of 2-way valve, N, which shifts to by pass pump now to tank. c) Re/irf-l'ah'e IIn/o(/;/ing, /\lnw-presslIre relicr val ve, 1', l;igure 8.15, cOllllccled in parallel with the cylinder's head end, is set just high enough to retract the cylinder. When the cylinder is fully retractcd, 10w-prcsslIrc relier val ve, 1'. lInloads the pllll1p. With this lype 01' circuit, the machine operntor does not need to hold ; spring-centered dircclioll cOl1lrol v:dvl' sllirkd 1IIIIillhc cylilldcr is rully retracted.
lnertia load

IIllloadillg. Ir 3-position, d) MII/lip/e-cy/inder . 2-way, normalIy-open vaIves are arranged in sei'ies with each main directional control valve, Figure 8.16, the system relief valve will be vented whcn all directional control val ves are in neutral. IIowever, {rany on~ orthe main directional conlrol val ves is shifted, the venl line will be blocked. The Illllllhcr or vellling val ves thal can b~ pul in series islilllit.ed-by the backpressure across each valve.

SYSTEM- PRESSURE DROP CONSIDERATIONS Pressme dropJ is a reduction in pressllre between [wo conscclIlive points in a Ouid power systelll.
Jlhid:

rr 77.

79. R-IOO. 1.'iO-17

M,

M,

Fig. 8.13. Two-way. NC directional Icm I elief valve lo unload pump.

control

va/ve venls

5)1S-

C,

Make up pnll

C,

Fig. 8.11. Brake valve consists 01 two, cross-piloled counterbalance valves which aprJly 1JlcklJlcssure lo decelerrtlc Ihe fluid molor under overrunning conditions caused by an inerlia load. The check valves cross reed retum oil lo minimize motor cavitation Elecllir:
switch

fig. 8.11. I1ccumulalor and closedcentor diroc(ional control valve l/I.1intain prosel s}'stem prcssure. t
Pressure connection

Fig. 8.12. Pressure sensing, tuales solenoid-controlled level is reached.

electrical pressure swilch acvalve when presel pressure

51

Pressure drap happens beca use so me energy in lhe syslem is required lo do work lO mainlaill fluid tlow agaillsl a resislance. This resistance C<1I1 be inlernal fluid friction, orifice-like reslritlioIlS in the tlow palhs, or exlernal load resislance. A pressure drop belween a pump ano molor represenls. a los s in energy which manifesls itself as heat. The pressure drop across lhe molor retlecls lhe energy being lransferred lo lhe external load. Molor el'Jiciency is an indic;llilln Ilr internal 01' lhe losses which redllcc lhe ,lcJual cnergy mOlor and lhe energy available ror lransrci'. The preSSUi'e drop across a given valve vai'ies ;IS the ralio oflhe speciric gravily ofllle rhlid. Ir, rni' 6/,1, inslance, we know lhe presslIre dillercnli;tI, for a fluid with a specific gravity Sg 1, then we can approximate lhe vallle of /1p2 for a secano nllid from the expression:
/1P2

Application

problem 1

AsslIme lhal flow rate lhrollgh valve is 1.2 gpm al a presslIre 'drop of SO psi. Whal wOllld be lhe pressure drop al a flow rale of 8 gpm? First, determine lhe ralio oflhe tlow rales: 8/1.2 = 6.66: l. The square of this ralio is 6.662 = 44. Thlls lhe pressure
/1/)~

~i

drop

al 8 gp'm wOllld be

= 50 x 44 = 2200 psi.

The designer lllllst he ,tlerl lo lhe dramatic increasc in preSSllrc dr(lps wliicll'can (lCCllr wilh seelllingly sm;dl inc'-;ases in Ilow' rate. ()ne such place is in lhe i'ellll'lllin<.: rrolll a cylinder. lrpllmp Ilow In Ihe he,ld end is r<;/leclcd across Ihe area dilTerenlial oflhe pislon, Ihe resuit can be a retllm tlow severa) time's grealCr than pump rate.

Application
Ass\lme .

problem2
a cylinder wil il ,\ S-in bore ami 3-in

= /1pl

(SlIjS!I)'
;IS

Similarly, lhe pressllre of flow rale:

(lrop-varies

the sqlla're

diameler rod. A pmp Sllpplies Iluid [O lhe cylil~-_ der al a rle of lO gpm. Detei'inine lhe piston' velocity during exlensioIl am! retraclion slrokcs. Whal will be llie Ilow rate nI' the relurning oil Ir the direclional dllring lile relractiuIl slroke'! control val ve experienccs a pressure drop of 20 psi al 10 gpm, what will be lile pressllre Jrop dllring rel'lIrn Ilow') . Piston velocily during Ihe exlension stroke is ',. =: Q.lA l' '--'- 1(10 gplll x 231 in! galll /19.6 in2

= I Ig ipm.
DlIring the retraction flllid is
l' ,.

slroke,

relllrn

velocily

ofthe

= QlA l'
[(10

A ,.
x 231 in!/gal))
/(19.6-7.1
in2)

gpm !l)5 ipm.

Fig. 8.15. Low pressure re/iet va/ve P (connecled in para/le/ witll cylinder)
1111108(15 pllf1ll'.

Flow rale during Ihe retraction Q,. =AI,I'r = 19.6 in2 x 185 ipm = 3626 in! Imin

stroke

is:

IS.7

gpm
way lo caICl"~11<.; pisto n vclocily is:

Al10lher

Fig. 8.16. If NO va/ves are arranged in series with each main directional.valve, system reliet valve is vented when all directiona/ valves.arein neutral.

52

-'1

Qr

= QAp/(Ap-Ar) = [(10 gpm x 19.6 in2))112_.Sin2 = 15.7 gpm.

the pressure
[tJ.} 1 (Qz/Q )2)

Inlerface

Hence, be:
tJ.) z

drop during retum f10w will

20 x (15.7 gpm/l0)2 49.2 psi.

F

/
~
1

The Force-Balance Concept A review of pressure controls. reveals that control val ves work on the principIe of a hydraulic force acting againsl a mechanical .spring. -This is known as the Force-n%J/ce concept, Figure R.17. I! is essential lo lIndersland and remember lhal whcn working with prcsslIre conll"Ols, ami, ;, for that matter, all nuid power components, we '... " " j'J .) lre ~g. with meclwncal dcvices. They all :;.-z,i,L',. work on the FORCE-BALANCE principIe. ( A hydraulic force can be developed on one side of a control element (intelface), as for example the poppet in a .relief valve, the spool in a reduicng valve-or in a sequenceyalve. The magnitude ofthe hydraulic force equals lhe product of the pressure difTerential across the elernent (lIof just inlet pressure) and the effective area of the element on which the pressure fluid acts. This relatiorship is expressed by ui~ Ir this hydralllic force were lInof1posed, the element would shift to wide-open position and f1l1d wOllld f10w through the control valve wilh vcry low pressurc (IIt111,-- jllsl Ihe cqlliv:dcnl orifice drop across the valve f10w path. To achieve any degree of conlrol, a Illcthod musl be provided to regulate lhe opening 01'lhe valve control orifice by lirniting the Illolion of the control element, i.e., f1of1pel or spool. This is ac dco.r""J.-, complsh~d by opposing the hyuraulic force~ ,0 spnng force, Figure 8.17. The force exerted by a j0j'\'.!"{) compression spring is expressed by the equation,
vi,...

~6X'

x,

Fig. 8_17_ Force-balance concept, Hydraulic lorce is equal to sum of product 01 pressure differential across the element and effective area of element on which the pressurized fluid acts.

tion based on tlle relationship:

tJ.}A .

FII

= F. =

K,

(Xi

11x,,).

FII

1\, uJAp

"

~/!/:"y'"

In this manner, a new eqllilibriulll position is established for each pressure generated in the f1uid power syslem. This relationship is plotteu as tlle curve in Figure 8,18. consideration, of particular mti. second portance when designing with energy1l1Ot!tJalillg-lype <,:ol1lrols, is Ihe cffcel of Ihe orifice now up characleristic, discusseu on page S}. Wilh respcct lo the force-balance principIe, il is imf10rlant lo recognize that the pressure referred to is aclually the pressure differential, up anoss the control elcment al a f1ow-rale lhat s equal to the amounl of f1uid actually passing through the valve. The relationship is expressecl rOllghlyas
UfJ

K"Q2,

where K, is the spring constant in lb/in, x. is the all101lnt o[ spring cOl11prcssion in inchcs, aml/'-" is lhe force in lb. Whcn designi ng hyd r:11 dic con! rols, 1he conlll10n pr:tclicc is to provide SOJ1lCnilial sprillg cOJ1lprcssion, x, lo est:llJlish a mnimull1 force level in lhe conlrol syslem. This relalionship translates to a minimum pressure drop, tJ.J, across the control element' lo bring the hydraulic force into .equlibriumwith the spring f9rce. In a relief val ve this force roughly corresponds lo the cracking pressure. As'-the control element moves offits seat dllring normal valve operation, thespririg compresses more, as'shown by ux." Figure 8_.17. This action establishes a new equilibrium posi53

ami is rerresented by Ihe curve shown in Figure X. IX. Tl1i.s curvc is lypic,dly c1wractcristic for a rclicf valvc. wl1ich illllslralcs lhc poin( IInde: discIIssi(ln. 111 :1 f(lrcc-hal:lI1ce syslell1l1sing a spring, sllcl1 as is C(l11l111l1nly Ilscd inllllid po\Vcr conlrols. it is inlJ111Ssihlc ror any reaclion lo happcll inslantaneously. :-'-'~- ).",A finite amount ofmovernent is always requireu for the valve to reestablish new equilibrium points along the curve. Such movement, along withthe changes in control orifice al-ea and by-passed flow rale associatedwith il, require some inerement of time, no matter how ittle. lJ:1.g.s.,relief valves do 1101 exhibil a slep-change characterslic relating_ pressure level and bypass now rate; ~er they

CL/'V"-

~'_"";'co~j':

~'-;:""",-'.

display an exponential c1laraclerisliL, :gme X, IX. Al ,1I1Y systelll IHcssllre bcluw lile u'ackilrg pressure, /),., the valve renl<lins l'lt)sed: Ilypass Ilow ralc, Q" = (), , Inthe rressure range bel\Yccn valve,ci'acking and setting,p('<ps,<Plllu,", by ras s Ilow rate will, .' . als'o'vary, O < Q/J/< Q,;ICU' 'When' full pump output, QIIICU' == 100% Q" is bypassing to lank, systcll1 pressureis at maximum, /)s('[: Thcse concepts arply in general, to all pressure III/l/llow controls lIsed in Iluid power syslems. We have extended the force-balance concept to its application to pressllre cOll1pens,lled 'plImps, Figure 8.19. Shown schematicully are a vane pllmp ano un axial-pislon, variahlc-displaccmenl, pressure-compensated pllmp', Thc .\print;. .fc)ree' rol' [he compensnt 01'conl rol is represen ted alleft, lhe /Iydml/lie juree al rigll'!. I:orce rclaliollships are plOlleo as typical clIrvcs below lhe pllmp representatiolls, The principal dilTcrcllce belween the pressure-compensat'eo PUlP and' the rehef' valve previollsly discllssed is lhat pUll1p pressure equals system pressllre: lhe relief valve works wilh a pressure drop across lhe relief valve poppe!. Pressure compensator Compensalor spring initiul condilions are illuslrated at upperleft, Figure 8,19. Spring free lenglh is sh6wn, and initial compression is labeled Xi' With a spring constanl, k", lhis reslllls inan inilial rorce 01' f-'" ~ k,y,";, whicl1 is plllllL'd lln lhc spnng I'orce Cllrvc al !en ccnlcr. Al right cenler 01' Figure X.19 is a 1'101 01' lile hydratilic cOlllpcns:llor pisllln I'llrCL:.Tl1e poinl on lhe spring I'orce curve COrrCSI)L)lIding.lu inilial compression is projecled ;cross lo hc' hydraulic rorce curve, Initial pressllre, /) would be syslem pressure which would jllst balance the spring force under initial condilions. If inilial pressure, /J, is cSlablislled as lile cutoff pressure for Ihe pressure compcnsaled pumr>, X is lhe amounl 01' r>recol.l1preSSiull reqllircJ lo

0"
Valva solling .. 100%

p,

p,

D.p
Cracking pressure,

p,

Fig. 8,18. In /orce-balance concepto fluid pressure is actual/y the pressure differential across the control element at a flow rate equallo the amount of ffuid actual/y passing throug/1 the valve.

determine cut-off. Any pressllre below cut-offwill not afrect pump displacemenL Pressures between cut-off ano deadhead will result in new eqllilibrium points being estabJished by additional spring compression. Simultaneously, [he displacement mechanism is adjusled lo reduce pump delivery. Tlle limil is deadllead pressure. At lhis point the plllllp SlllpS tklivering !luid lo lhe syslem alll)(lllgh l11aXillllll11preSSllre is maintaincd. Slcps I lhroll~h V in Figure X.J9, illllstrale lhe algebr;ic eLjualions rclaling spring I'orce and hydraulic compensator force. The characteristic curve [ right is Ihe lypical pressure compensated pump cllrve and includes indication ol' displacement condilions rol' each part 01' the curve. Thc hove describes direct acling compensator controls. Chaplers 14 and 15 discuss compensators which lIse modulaling valves ror control.

Review

Exercises

1,.

Whal Iwo types 01' control relale lo encrgy transfer in tluid power systems? 8.2. Which of lhe two syslem paramelcrs relating to the controls referred to in cxercise 8.1 deals with Ihe potenlial energy level ol' lhe Iluid in he system? H.3. To what parameter does the proLucI 01' pressure (psi) amI weight flow rate (lb/time) relate') What :\1,' the relatonsllips in SI lInis'?
H.1.

8.4. Whal are lhe two basic modes 01' pressllre control? 8.5 Lisl the basic kinds of pressure control valves uscd in Iluid pnwer systems. Define Iheir funclions brietly. Illustrate with ANSI graphic symbols. 8.6. What is the primary function of a pressure relief vlve in a fluid power system? 8.7. How is a relief valve sized for a circuit? 5.5. Di:cu:i;S lile oiffcrcnCC5 bctwccn a drect54

, i ,_ ~.I:'

':>'J -:

./,'.l. ./
Center line HYDRAULlC STROKING PISTON ENERGY SOURCE

SPRINGBIAS MECHANISM

~Free

ienglh~

Q"e
e = eccenlricity
{ _ 01 cam ring lo rotor SlId.lng vane pump

rx, ~_ I
I
Inilial

F,
k, ' ;,
",
.

H'l I I
I o

I compresslon ,I 01 spring
'
{

Q"

0,
= swash

0,

I I I

plate angle Axlal plston pump

x,

p,
'--'I"'- .
l.. '

p,
O

1'
Er]lIilitJriwlI rr.qllilp.s

'

p, " systern pressure Ihal

r; .,. , F
r, 1',1\,

1\,

r""cllvn
aren 01 .. ~. cqrnpensator [Jislon ~plillg C(1Il~I;1I11

K~

F,

F,

'. 1. 'Inilial condilions

~' ' F ~- .'

~

0--------, O

Displacemenl V, ~ K = maxirnum

K,x, ~~F'

'p,A, O

Q ='

VpN, V,

= maximurn

In Ihis pressure range, pump behaves like ~ lixed , displacemenl pump.

11. pressure, "cul-oll", Up lo Ihreshold

p, - p. '{

K,IX",

p,A, f 6x)
V, - K maximurn

111.1\1 cIII,oll"

r,

p,

K.,

l.,. 1 /,xl

IJ./\'

---------,----

IV.. 8olween

cuI,oll

~nd de~c1 he~ p,' p,' p~

K,lx,

6xI - p; A,

Purnp orerales on "cut'off" ponion 01 curve

V. 1\1 deadhead

p.'K,IX, '. p,/\,-------------------I 6.<,;1

p, 01 vano and axial pislon variable is al left, hydraulic force al righl. displacmenl, pressure

V" -

Fig. 8.19. Schemalic compensalor control

compensaled

pumps.

Spring

force

for

55

acting and a pilot-operated relid valve. Wh,1l ;lrc 01' each'.) Draw the advantages and disadvanlages the ANSI symbolsfor each. 8.9. Discuss "cracking band" 01' relief valvcs ;lllll ils significance in circuit applicaliolls. 8.10. What techniques are available lo minimize shock prcssures in a circuit? 8.1 l. Discuss the concept of valve control 01' pressure vs. pump controlof pressure. 8.12. What is meant by the "force-balance" concept? How does it apply in fluid power controls? 8.13. Discuss the difference in applicalion of "force-balance" in a "modulating" pressure control vs. a "switching" type pressure control. 8.14. Why is it erroneous to talk about "instantaneous" actions in a fluid power system ') 8.15. What is the function ofa reducing valve? Is it un energy "modulating" 01' "switching" type of pressure control? Draw its ANSI symbol. 8.16. What i5/are the diffence(s) between lhe two types of redllcingvalves? ... 8.17. What is the function ofa sequence valve? Is it an energy"modulatirig" ar "switching" lype al' pressure control? Draw the ANSI symbol for lhe sequence valve. g.lH. Once a scqucncc valve Ilas "scqllcllced". wll,al is lile rclationship bctwecn the pn:ssllrc

leve] in lhe primal)' anJ sccondary circuits? 8.19. Typically a manufacturer of a sequence valve mayspecify the "reset" pressure level 01' his valve as 85S'1, ofils actllalion pressllre. Discllss what Ihis means and its ill1plications in a circuil application. 8.20. What. is lhe fllnClion of a counlerbalance valve in a circui l? Is it a "ll1odlllaling" 01''' swilching" lype valve? Draw its ANSI symbol. 8.21. What is the fllllction of an unloading va]ve'? Is it a "modulating" 01' "switching" type 01' valve? Draw its ANSI symbol. 8.22. What is the function of a pressllre switch'? Draw its ANSI symbol. 8.23. Explain how venlng a relief valve can unload a crcuit. Draw a venling circuit lIsing ANSI' symbols. 8.24. Which types ofpressure control val ves must haye external drain ines connected to lank? 8.25. Discltss the effect of pressure differenlial(s) across controls in a circuit on: a. pump discharge pressure relative lO load pressure; b. efficiency 01' ; circuit. 8.26. Is it possihlc lo achievc a measlIrc nI' presslIre control with a dircclional conlrol valve by 1l10dlllating spool pnsilion? Explain.

r::;

56