Flow-control Flow control Valves

In order to control the velocity of a hydraulic motor or cylinder you have to control the flow. In this example p the flow to the cylinder is controlled by a simple flow control. control

Flow-control Valve
The pressure behind the flow control is determined by the load on the cylinder and is in this case 80 bar. The flow control adjusted on a flow of 8 l/min. l/min The hydraulic pump delivers 12 l/min so a part of the pump , 4 l/min flows through g the pressure p relief valve back flow, to the reservoir. pressure before the flow control is determined by y the The p pressure relief valve, in this case 120 bar. The pressure drop in the flow control (40 bar) and in the pressure relief valve (120 bar) is converted into heat. This kind of flow control is relatively cheap but has a low energy efficiency.

Needle Valve

The simplest and most common of the flow restricting valves is a simple needle valve. This type of valve consists of a valve body that contains an orifice and a tapered stem (or needle), needle) which can be screwed in and out to vary the orifice opening. The symbol shown represents all of the simple restrictor type valves, regardless of the actual restrictor mechanism.

Needle Valve

Needle Valves
A simple needle valve restricts flow in both directions through the valve, There is, however, a preferred direction of flow, normally indicated by an arrow on the valve body. When the flow is in this direction, the pressure loss across the valve is slightly less and the valve is self-cleaning and not likely to accumulate contaminant particles that might build up and restrict flow. flow The addition of an internal check valve allows for restricted flow in one direction and free flow in the other direction (Figure ( g 9.2). Flow entering the P port of the valve is obstructed by the check valve and directed through the metering orifice. When flow is reversed reversed, the fluid enters the F port port. Flow in that direction opens the check valve and flows freely through the valve. No control is exerted in the reverse direction, , so the valve must be sized to accommodate the maximum flow that can be expected in that direction.

Needle with check

A needle dl valve l with ith an internal i t l check h k valve l allows for restricted flow in one direction and free flow in the other direction.

In a simplified equation (often referred to as the orifice equation) we bring these factors together to define the flow rate through the orifice as

Q C A

2 gp

where h C is a constant that h is a characteristic h of f the h particular l orifice design, A is the area of the orifice, g is the acceleration of gravity and is the specific weight of the fluid. gravity, fluid For any given orifice, C and A are fixed, g remains constant, and the specific weight is relatively constant for an operating fluid. fluid That leaves only the differential pressure as a variable parameter. This presents a major disadvantage in trying to use a fixed orifice as a control device in common fluid power systems. Any time the pressure differential across the orifice changes, the flow rate through h h the h orifice changes. h As we have h seen, the h speed of any actuator (motor or cylinder) depends on fluid flow rate. Thus, if the upstream pressure varies for any reason or if the downstream pressure varies (as will happen if the load changes), then the speed of the actuator changes.

To help T h l overcome m this problem, bl m devices d i s such s h as s needle dl valves l s are used. Needle valves are nothing more than variable orifices that use the stem m to change g the size of f the orifice. f This g gives us the ability to compensate for changes in the differential pressure in order to maintain a constant flow rate through the valve and, consequently, s tl a constant st t actuator t t speed. s d It also ls allow ll us s to t establish a desired flow rate without removing a fixed orifice and replacing p g it with one of f a different ff size. The ability to vary the orifice size in a needle valve also causes the orifice constant, C, to change.

A drawback of simple needle valves is their response to changes in pressure differential. Fig. 9.4 shows the pressure-flow characteristics of a typical needle valve. It is obvious from the plot that this valve provides no real measure of control unless the pressure differential remains constant. While a constant pressure differential might occur in many fluid transfer and process operations, it is not typical of most working fluid power systems. The normal working system may require more sophisticated flow control than can be provided by a simple needle valve. A pressurecompensated flow control valve is often necessary.

Pressure-Compensated Pressure Compensated Flow Control Valves

The difference is that there is a sliding spool on the inlet side of the pressure-compensated valve. As the upstream pressure increases, a force is exerted on the face of the compensating spool that causes it to slide back into the control cavity and partially restrict the control orifice. An increase in the downstream pressure pushes the spool the other way. The purpose of the compensator is to create a pressure d drop that h keeps k the h pressure differential diff i l across the h adjustable dj bl needle dl valve constant- usually about (689.5 kPa). This allows the valve to g the pressure p maintain a constant downstream flow rate even though drop across the entire valve may be changing frequently and over a wide range. In Fig Fig. 9 9.6, 6 each line in the family of curves represents a different valve setting. Notice that there is an apparent increase in the flow rate at the lower pressure settings. This occurs because of the positive f force exerted x t d in i the th compensator mp s t spool sp l by b the th spring. sp i Until U til the th inlet i l t pressure is high enough to generate sufficient force to begin to compress the spring, the valve acts as a simple needle valve. The valve also acts as a simple needle valve if the flow is backward through it.

Pressure-Compensated p Flow Control Valves

A pressure-compensated pressure compensated valve provides more stable flow control than a simple needle valve.

Performance
It is obvious that a pressure-compensated valve would be much more s it bl th suitable than a noncompensated valve in any system y where a steady y actuator speed is required. Th s valves These l s will ill typically t i ll maintain output flow within + 5% of f the selected setting over a wide pressure range. This is sufficiently s ffi i tl accurate t for the majority of industrial and m mobile equipment applications.

Typical T i l pressure-compensated ss s t d flow control valve performance

The controlled Th nt ll d flow fl di direction ti n will ill b be clearly l l indi indicated t d on n th the valve by either an arrow on the valve body or by marking the inlet and outlet ports. p

Two-port Two port pressurecompensated flow-control valve

The pressure compensated flow control

The pressure compensated flow control

The pressure compensated flow control

The pressure compensated flow control

To control the velocity of a hydraulic motor or cylinder one has to control the flow to these components. This can be done with a simple fl flow control t l The flow through a flow control is determined by: a) The area of the flow control: a larger area means a higher amount of flow and b) the pressure drop across the flow control: an increase of the pressure drop p p means an increase of flow Example: in a system with a flow control the pressure at the pump side is determined by the pressure relief valve (see also flow control). When the pressure drop across the flow control decreases as a result of an increase of the load on the cylinder the flow and velocity of the cylinder will decrease. If the velocity has to remain constant and independent of th l the load d one h has t to use a pressure compensated t d flow fl control t l How does it work? h pressure pr ssur at the th out outlet t of th the pr pressure ssur comp compensated nsat f flow ow control contro is s The determined by the load on the cylinder. The load is 50 bar and increases to 90 bar when the mouse cursor is put on the picture. The pump pressure pressure, determined by the pressure relief valve is 120 bar. bar

The p pressure compensated p flow control

The pressure compensated flow control is adjusted on 10 l/min. The pump p p delivers 12 l/min: this means that the a flow of 2 l/min flows through h h the h pressure control l valve l back b k to the h reservoir. i The pressure compensated flow control has two parts: a flow control (the needle valve) ) and a p pressure reducing g valve or pressure p valve ( compensator. The desired flow is adjusted with the needle valve. The pressure compensator with spring loaded plunger at the left pressure at the inlet of the needle valve (p p2). At side measures the p the h right i h side id of f the h plunger l the h pressure of f the h load l d (p ( 3) and d of f the spring are pushing the plunger to the left. The pressure of the spring is 8 bar. Th plunger The l finds fi d it's it' b balance l when:p h 2 = p3 + pspring ==> p2 - p3 = pspring and because of the fact that pspring= constant (8 bar) the pressure compensator keeps the pressure drop across the needle valve on a constant value of 8 bar. bar This means that the flow through the needle valve remains constant! When the load increases the pressure p3 increases and the plunger i out is t of f balance b l and d pushed h d to t the th left. l ft Th Then the th pressure p2 will ill increase as well and the plunger finds it's balance again. The p pressure drop p across the needle valve is still 8 bar so the flow remains 10 l/min l/ and d therefore h f the h velocity l of f the h cylinder l d remains constant and independent of the load!!

By-pass (three-port) flow control

Advantages Ad nt s of f this valve l over th the restrictor-type st i t t p valves l s are reduced heating of the fluid and a significant reduction in the horsepower p input p required q during g portions p of f the operating p g cycle. y

By-Pass (three-port) - Dump Valve

A motor using a Bypass flow control valve

Flow Control Valve Applications

Flow control valves regulate the speed of a hydraulic actuator by g the volume flow f rate to the actuator. This can be controlling accomplished in three ways: 1. Controlling the flow rate into the actuator (termed meter-in). 2 Controlling 2. C t lli th the fl flow rate t out t of f th the actuator t t (t (termed m dm meter-out). t t) 3. Diverting a portion of the fluid before it reaches the actuator (termed bleed-off). ( ff) In some instances, a combined meter-in and meter-out circuit may be used. Q Question: ti : If the th flow fl control t l valve l is s set tt to pass ss 5 gpm m,b but t th the fixed displacement pump has a 10 gpm flow rate. Where is the other 5 gpm going? g g The only place it can go is through the relief valve and back to the reservoir. For it to do that, there must be sufficient pressure to open the th relief li f valve. l If the th relief li f valve l is s set t at t 2000 psi, si so s we can assume that the pressure in the circuit is 2000 psi.

Flow Control Circuits

In a meter-in circuit, a flow control valve is placed in the line to the inlet port of the actuator. The actuator may be either a cylinder, cylinder rotary actuator actuator, or a hydraulic motor. A meter-in circuit of a cylinder is shown in. Adjusting the valve setting varies the flow rate into the cylinder. Meter-in circuits are normally used only in those arrangements where the load is always resisting the force of the actuator. Where the force is not resistive, as in the case of a suspended load, it is possible for the load to drop uncontrolled, even if the meter-in valve is fully closed.

Meter-in speed control (extending) works by means of a flow control valve placed in the inlet line of the actuator.

The valve placed in the outlet line controls the rate at which the fluid leaves the actuator (Keep in mind that the terms actuator. inlet and outlet depend on the direction of travel of the cylinder.) The meter-out technique is usually preferred over the meter-in technique because it adds stability to the circuit and eliminates the possibility of a suspended load running away. The meter-out circuit presents the likelihood of pressure intensification when the cylinder is being extended extended. Because the flow control valve restricts the outlet flow, a back-pressure results on the rod Meter-out speed control end of the cylinder. The degree of intensification depends on the load, the (extending) works by restriction and the size of the rod means of a flow control flow restriction, valve placed in the outlet relative to the piston. line of the actuator

A meter-out circuit is shown.

Flow control circuits

You must be very careful in how you use meter-out flow controls for two reasons-: very high pressures may result due to pressure intensification in the cylinder and the accompanying pressure drop across the valve l may cause a high h h rate of f heat h generation. Figure 9.12 shows a circuit in which a three-port flow control valve (by (by-pass pass valve) is used. used This type of valve can be used only on the inlet side of the actuator. A major advantage of the three-port valve is that the system t pressure i is d determined t i d entirely ti l b by th the l load d and d never exceeds that required to move the load. In circuits utilizing the two-port p flow control valves, the pressure p upstream p of the valve will continue to rise until it reaches the setting of the system relief valve. A major disadvantage is that three-port valves do not provide great accuracy in speed control. This type of speed control is unsuitable for parallel circuits where there is more than one actuator.

This th Thi three port t flow fl control t l valve l can be used only on the inlet side of the actuator. actuator

A variation on the use of a port flow control valve is shown in Fig. Fig 9.13. 9 13 In this circuit, termed a bleed-off circuit, a restrictor type flow control valve is used, but it is connected in parallel with the line leading to the cylinder.

 The outlet port of the valve dumps directly to the reservoir. Thi provides This id a flow fl path th by b which hi h the th excess flow fl (not ( t needed d d to operate the cylinder) can return to the reservoir without going g g through g the relief valve. The advantage g of this bleed-off circuit is that, as with the three-port valve, the load rather than the relief valve determines the system operating pressure.

Pressure Drop

There is a pressure drop through any flow control valve that results in horsepower p loss and heat generation. g In a meter-in circuit, for example, the pressure drop across the flow control valve depends on the force required by the actuator. If there is no load on the cylinder in Fig Fig. 9 9.14, 14 the pressure at the control valve outlet is essentially zero. The result is a high pressure drop that results in a high horsepower loss. As the load increases the force required to move the load increases increases, increases, so the pressure in the portion of the circuit between the valve and the cylinder increases. The pressure drop decrease means that th there is i less l horsepower h lost l t and d less l heat h t generated. t d What Wh t happened to the horse power difference between the two cases? It was used to do useful work in lifting g the load.

When a three-port flow control valve is used, the system pressure is governed by the force required to move the load. Consequently, the pressure drop across the valve will be much less than that across a meter-in valve. valve Thus, Thus if the somewhat less precise control of a bleedoff type flow control can be tolerated, significant energy savings can be realized. As the previous example shows, this decreased pressure drop will also reduce the heat buildup in the system.

Combined Effects of System Pressure Drops

In this chapter, we have looked at the pressure drops and heat generation associated with flow g f control valves. And we looked at those same things for pressure control valves. In the real world, though, these are not separate, unrelated events. Instead, the pressure ss drops d s across ss b both th types t s of f valves, l s and, d indeed, i d d every other device in the circuit combine to give the total heat generation rate for g f the system. y In a normal system, much of this heat will be dissipated through the components, reservoir, and system piping, but it may be necessary to add an oil l cooler l (h (heat exchanger) h ) if there h is not sufficient natural dissipation.

Flow Regulator (Pneumatic)

Uni-directional Uni directional, line mounted adjustable flow regulator Free flow in one direction Adjustable restricted flow in the other di direction i

Free Flow

Flow Regulator (Pneumatic)

Uni-directional Uni directional, line mounted adjustable flow regulator Free flow in one direction Adjustable restricted flow in the other di direction i

Controlled Flow