Lab Report - 1

Aim: Study of external gear pump and an unbalance vane pump generally used
in oil hydraulic systems

External Gear pump

Theory
A gear pump is a type of positive displacement (PD) pump. Gear pumps
use the actions of rotating cogs or gears to transfer fluids. The rotating gears
develop a liquid seal with the pump casing and create a vacuum at the pump
inlet. Fluid, drawn into the pump, is enclosed within the cavities of the rotating
gears and transferred to the discharge. A gear pump delivers a smooth pulse-free
flow proportional to the rotational speed of its gears.

An external gear pump consists of two identical, interlocking gears supported

by separate shafts. Generally, one gear is driven by a motor and this drives the
other gear (the idler). In some cases, both shafts may be driven by motors. The
shafts are supported by bearings on each side of the casing.

Fig. - External gear pump

Working Principle
There are three stages in an internal gear pump’s working cycle: filling, transfer
and delivery.

1. As the gears come out of mesh on the inlet side of the pump, they create
an expanded volume. Liquid flows into the cavities and is trapped by the
gear teeth as the gears continue to rotate against the pump casing.

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 2. The trapped fluid is moved from the inlet, to the discharge, around the
casing.

3. As the teeth of the gears become interlocked on the discharge side of the
pump, the volume is reduced and the fluid is forced out under pressure.

No fluid is transferred back through the centre, between the gears, because they
are interlocked. Close tolerances between the gears and the casing allow the
pump to develop suction at the inlet and prevent fluid from leaking back from
the discharge side (although leakage is more likely with low viscosity liquids).

Fig. External gear pump operation (arrows indicate the direction of the pump and liquid)

External gear pump designs can utilise spur, helical or herringbone gears. A
helical gear design can reduce pump noise and vibration because the teeth engage
and disengage gradually throughout the rotation. However, it is important to
balance axial forces resulting from the helical gear teeth and this can be achieved
by mounting two sets of ‘mirrored’ helical gears together or by using a V-shaped,
herringbone pattern. With this design, the axial forces produced by each half of
the gear cancel out. Spur gears have the advantage that they can be run at very
high speed and are easier to manufacture.

Advantages

 High speed
 High pressure
 No overhung bearing loads
 Relatively quiet operation
 Design accommodates wide variety of materials

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Disadvantages

 Four bushings in liquid area

 No solids allowed
 Fixed End Clearances

Applications

Common external gear pump applications include, but are not limited to:

 Various fuel oils and lube oils

 Chemical additive and polymer metering

 Industrial and mobile hydraulic applications (log splitters, lifts, etc.)
 Acids and caustic (stainless steel or composite construction)
 Low volume transfer or application
 Water.

 Various fuel oils and lube oils (engine and gear box lubrication
systems).

 Chemical additive and polymer metering.

 Chemical mixing and blending.

 Industrial, agricultural and mobile hydraulic applications (tractors, log

splitters, lifts, etc.)

 Acids and caustic (with stainless steel or composite construction).

Resins and polymers.

 Alcohols and solvents

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Unbalanced Vane Pump

Theory
Vane pumps are well known for their dry priming, ease of maintenance,
good suction characteristics, and are a popular choice for low viscosity
applications. They're available in a number of vane configurations, including
sliding vane, flexible vane, swinging vane, rolling vane, and external vane. Each
type of vane pump offers unique advantages when it comes to specific
applications. For example, an external vane pump is great for handling large
solids. On the other hand, flexible vane pumps can only handle small solids, but
create a good vacuum. Sliding vane pumps can run dry for short periods of time
and handle small amounts of vapor.

Working Principle
Initially, the rotor is connected to a driving shaft is rotated using external power
source. The rectangular vanes commies 0111 of the slots due to centrifugal force
and touches the surface of the cam ring. Thus, the pumping chamber is divided
into equal number of small chambers.

First Half of Rotor Rotation

During the initial rotation of the rotor, the volume of chamber increases due to
the outward movement of the vanes and the pressure is less than the atmospheric
pressure. This creates suction at the inlet and the fluid enters into the suction
chamber. Then, the fluid is transferred to the pumping chamber.

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Second Half of Rotor Rotation
During the second half of rotor rotation, the rectangular vanes are pushed back
into the slots of rotor. Thus, volume is reduced and the pressure is increased. The
fluid is forced out of the pump positively through the discharge chamber (e, outlet
port). The pumping action of unbalanced vane pump Le, delivery rate of the pump
can be varied by changing the offset distance (eccentricity) between rotor and
cam ring.

Fig. – Vane Pump

Advantages of Unbalanced Vane Pump

 Compact in shape
 Relatively less weight
 Can be used for less viscosity fluids Le, vapour and gases
 High volumetric and mechanical efficiencies
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  Leakage of fluids is greatly reduced
 It is a bi-directional pump
 Replacement of vanes is very easy
 Check valves are not required.

Disadvantages of Unbalanced Vane Pump

 Cannot be used for the fluids with solid particles (abrasive fluids).
 Requires relief valves.
 Good seals and filtration systems are required.

Application

 Vane pumps are used in beverage processing machines.

 These pumps are used in oil and gas applications.
 A vane pump is employed in a lubrication system for the
equipment and machine. It provides a steady flow of lubricant to
lower wear and friction.
 Vane pumps are also used for mid-range pressure applications
such as dispenser machines (espresso, coffee, and soft drinks).
 The rotary vane pumps are used in Aerosol and Propellants.
 These pumps are most widely utilized for high-pressure
applications such as power steering, air conditioners, and
superchargers.
 These pumps are used for the filling of the LPG cylinders.
 Vane pumps are most commonly used in heating, ventilation, and
HVAC systems for moving a coolant such as a refrigerant or
water.
 They are used for bulk transferring of NH3 and LPG.

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 Lab Report - 2
Aim: Study of rotary screw type and vane type compressor generally used in
pneumatics system.
Rotary Screw Type Compressor
Theory
A rotary screw type compressor is a type of positive displacement
compressor commonly used to compress gases, most notably air. It is widely used
in various industries for applications that require a continuous and reliable supply
of compressed air.
The basic principle behind a rotary screw compressor involves two helical rotors
(screws) placed inside a cylindrical housing. One rotor is the male element, while
the other is the female element. These rotors are precisely machined to fit closely
together without touching. As the rotors rotate, the air gets trapped between the
helical lobes and the housing, and it is progressively compressed as it moves
towards the discharge port.
The compression process in a rotary screw compressor is continuous and delivers
a steady flow of compressed air. This differs from reciprocating compressors,
which operate in a pulsating manner. The continuous operation of rotary screw
compressors makes them suitable for applications with high air demand and a
requirement for constant pressure.
There are two primary types of rotary screw compressors:
1. Oil-injected rotary screw compressors: In this type, a lubricating oil is
injected into the compression chamber to seal and cool the compression
process, reduce friction, and improve efficiency. The oil also helps to
absorb heat generated during compression and carry it away from the
compressed air. The compressed air and oil mixture is then separated, and
the oil is recycled back into the system. This design provides better
efficiency and is commonly used in industrial settings.
2. Oil-free rotary screw compressors: These compressors do not use oil in the
compression chamber. Instead, they employ special materials, coatings, or
advanced technologies to ensure the rotors don't come into contact with
each other. This prevents oil contamination of the compressed air and is
essential for applications where oil-free air is required, such as in
pharmaceuticals, food processing, electronics manufacturing, and some
medical applications.

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Rotary screw compressors are versatile, reliable, and capable of handling a wide
range of air demands. They are used in various industries, including
manufacturing, construction, automotive, aerospace, and more, to power tools,
machinery, pneumatic systems, and other applications that rely on compressed
air.

Working Principle

The working principle of a rotary screw type compressor involves the use of two
helical rotors (screws) that rotate inside a cylindrical housing. These rotors are
precisely machined and have a specific helical shape. One rotor is the male
element, and the other is the female element, and they fit closely together without
touching each other.

Here's a step-by-step explanation of the working principle of a rotary screw

compressor:

1. Intake of Air: The compressor draws air from the surrounding environment
through an inlet port.

2. Compression: As the rotors rotate, the helical lobes of the male rotor mesh with
the helical grooves of the female rotor. As the rotors rotate, they create pockets of

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trapped air between the lobes and grooves. As these pockets move towards the
outlet end of the housing, the volume between the rotors decreases.

3. Volume Reduction and Compression: As the air pockets move towards the
outlet, the space between the rotors gets smaller, resulting in a reduction in the
volume of the trapped air. This reduction in volume causes the air to be
compressed. The compression is continuous, providing a steady flow of
compressed air.

4. Oil Injection (for oil-injected compressors): In oil-injected rotary screw

compressors, a small amount of lubricating oil is injected into the compression
chamber. The oil serves multiple purposes: it helps seal the gap between the
rotors, reducing leakage, it cools the compressed air and the compressor itself,
and it lubricates the moving parts, reducing friction and wear.

5. Discharge: The compressed air continues to move towards the outlet end of the
housing. When it reaches the discharge port, it is forced out of the compressor
and into the air system for various applications.

6. Oil Separation and Cooling (for oil-injected compressors): In oil-injected

compressors, the compressed air and oil mixture leave the compression chamber.
The mixture then goes through a separation process, where the oil is removed
from the compressed air. The separated oil is recycled back into the system, and
the compressed air proceeds to further processing and cooling stages.

7. Oil-Free Compression (for oil-free compressors): In oil-free rotary screw

compressors, the rotors are designed with special coatings or materials that
prevent contact between the rotors. This eliminates the need for lubricating oil in
the compression chamber and ensures that the compressed air remains oil-free.

The continuous rotary motion of the helical rotors allows for a steady and reliable
supply of compressed air, making rotary screw compressors suitable for
applications with high air demand and a requirement for constant pressure. They

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are widely used in industries for powering various tools, machinery, and
pneumatic systems that rely on a continuous supply of compressed air.

Advantages
1. Continuous operation
2. High efficiency
3. Compact design
4. Low noise level
5. Low vibrations
6. Reliability and durability

Disadvantages
1. High Initial Cost
2. Sensitivity to contaminants
3. Limited to certain applications
4. Difficulties in achieving high pressure
Applications
Screw compressors are versatile machines that find applications in various
industries and processes. Their efficiency, reliability, and continuous operation
capabilities make them suitable for a wide range of tasks. Some common
applications of screw compressors include:

1. Industrial manufacturing: Screw compressors are widely used in industrial

manufacturing processes, such as automotive, aerospace, electronics, food and
beverage, and pharmaceutical industries. They provide a steady source of
compressed air for powering pneumatic tools, air-operated machinery, and
production lines.

2. Refrigeration and air conditioning: Screw compressors are utilized in large-

scale refrigeration and air conditioning systems, including commercial and
industrial cooling applications. They play a crucial role in generating the
necessary refrigeration cycle to cool or freeze products and maintain controlled
temperatures in various environments.

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3. Gas and oil processing: In the oil and gas industry, screw compressors are used
for natural gas compression and processing, including gas gathering,
transmission, and storage. They help increase the pressure of natural gas for
transportation through pipelines or for liquefaction.

4. Wastewater treatment: Screw compressors are employed in wastewater

treatment plants to provide aeration for the activated sludge process. The
compressed air is introduced into the treatment tanks to facilitate the growth of
microorganisms that help break down organic matter.

5. Power generation: In some power plants, screw compressors are used in

combined cycle systems or gas turbine applications to compress air for
combustion in the gas turbines. This improves the overall efficiency of the power
generation process.

6. Chemical and petrochemical industries: Screw compressors are utilized for

various processes in the chemical and petrochemical industries, including
supplying compressed air for chemical reactions, pneumatic conveying of
materials, and process gas compression.

7. Mining and construction: Screw compressors are used in mining and

construction operations to power pneumatic drills, hammers, and other tools used
for excavation, drilling, and rock-breaking tasks.

8. Printing industry: Screw compressors are employed in the printing industry to

provide compressed air for powering printing presses and equipment, ensuring
smooth and precise operations.

9. Rail and transport: Screw compressors are used in rail and transportation
systems to supply compressed air for braking systems, air suspension systems,
and other pneumatic components.

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10. Energy storage: In some renewable energy applications, screw compressors
are used as a part of compressed air energy storage (CAES) systems, which store
excess energy during low-demand periods and release it during peak demand,
contributing to grid stability.

These applications highlight the widespread use of screw compressors across

various industries, making them essential components in modern industrial
processes and infrastructure.

Vane Type Compressor

Theory
A vane-type compressor, also known as a rotary vane compressor, is a type of
positive displacement compressor used to compress gases. It operates on the
principle of using rotating vanes (blades) inside a cylindrical housing to trap and
compress the gas.
Working Principle
Here's how a vane-type compressor typically works:
1. Rotor with Vanes: The compressor consists of a rotor mounted
eccentrically inside the cylindrical housing. The rotor has slots in which
vanes are fitted. The vanes are free to slide in and out of these slots.
2. Compression Process: As the rotor rotates, the centrifugal force pushes the
vanes against the inner wall of the housing, creating a seal between the
rotor and the housing. This forms individual compression chambers
between the vanes.
3. Suction: During the suction or intake stroke, the rotation of the rotor causes
the volume of the compression chamber to increase. This creates a low-
pressure area, and gas from the outside is drawn into the chamber through
the inlet port.
4. Compression: As the rotor continues to rotate, the volume of the
compression chamber decreases, compressing the gas trapped inside. The
gas gets compressed as the vane approaches the discharge port.

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 5. Discharge: Finally, the compressed gas is expelled through the discharge
port as the vane moves away from it.

Advantages of Vane Compressor

1. Simple design
2. Easy to install
3. Very few moving parts
4. Low rotational speeds
5. Low maintenance cost
6. Low to Medium cost
Disadvantages of Vane Compressor
1. Oil injected designs have oil carryover
2. Single stage designs have lower efficiency
3. Difficulty with high pressures
4. Oil free designs are unavailable

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Applications of Vane Compressor

Vane compressors, also known as rotary vane compressors, are widely used in
various applications where moderate compression is required. Their smooth
operation, compact design, and reliability make them suitable for a range of
industries. Some common applications of vane compressors include:
1. Air Conditioning and Refrigeration: Vane compressors are used in small-
scale air conditioning and refrigeration systems, such as domestic and
commercial refrigerators, freezers, and air conditioners.
2. Pneumatic Tools: Vane compressors are employed to power pneumatic
tools like impact wrenches, air hammers, nail guns, and sanders used in
construction, automotive, and manufacturing industries.
3. Dental and Medical Equipment: Vane compressors are used in dental
offices and medical facilities to provide a source of compressed air for
various dental tools and equipment, such as dental drills and air syringes.
4. Food and Beverage Industry: Vane compressors are utilized in the food and
beverage industry for applications like packaging, bottling, pneumatic
conveying, and food processing equipment.
5. Printing and Packaging: Vane compressors play a role in powering printing
presses and packaging machines, where they provide compressed air for
various pneumatic components.

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 Lab Report - 3
Aim: Study of Pressure Control Valves generally used in oil hydraulic /
pneumatic system.

Pressure Control Valve

Theory
The valves enable the regulation of system pressure to adjust the force
on a hydraulic piston rod or the torque on a hydraulic motor shaft. Pressure
relief valves are used to set the maximum pressure in the circuit and protect
it from overloading. Pressure reducing valves permanently maintain the
output pressure at the set value while protecting the appliance from
overloading. Unloading valves are designed for economical pressure control
in accumulator-operated circuits that serve as a power source for emergency
control.

Fig. – Pressure Control Valve

Working Principle
A mechanical spring holds the flow of fluid in a direct acting valve. Here, the
spring force and the hydraulic pressure work against each other in limiting
the flow. Using the knob, you can change the tension in the spring which at a
certain limit will result in the opening of the valve. The pressure at which the
valve opens is the cracking pressure. As you overcome the cracking
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pressure fluid will begin to pass through. At the full relief valve pressure, the
valve is fully open permitting the maximum flow of liquid.

Fig. Pressure Control Valve Working

Advantages

 Pressure control valves help to regulate the pressure in a system.

 Pressure control valves can help to improve the efficiency of a system
by preventing pressure build-up.
 Pressure control valves can help to protect equipment from damage
by preventing excessive pressure.
 Pressure control valves can help to reduce energy consumption by
preventing pressure loss.
 Pressure control valves can help to improve the safety of a system by
preventing over pressurization.

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Disadvantages

 Pressure control valves can be expensive.

 Pressure control valves can be difficult to install.
 Pressure control valves can be difficult to maintain.
 Pressure control valves can be prone to leaks.
 Pressure control valves can restrict flow.

Applications
Common application of pressure control valve includes, but are not limited to:

 It can limit the maximum pressure

 Backpressure can be set
 These valves would send a signal if the set pressure is reached
 It can protect the pump or system for overpressure
 It can unload a pump
 These valves can set pressure at which oil enters a circuit

Types of Pressure Control Valve :

There are mainly three types of valve available –
1. Pressure Relief Valve
2. Unloading Valve
3. Pressure Reducing Valve

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1. Pressure Relief Valve:

This type of valves has two ports; one of which is connected to the pump and
another is connected to the tank. It consists of a spring chamber where
poppet is placed with a spring force.
Generally, the spring is adjustable to set the maximum pressure limit of the
system. The poppet is held in position by combined effect of spring force and
dead weight of spool.
As the pressure exceeds this combined force, the poppet raises and excess
fluid bypassed to the reservoir (tank). The poppet again reseats as the
pressure drops below the pre-set value. A drain is also provided in the
control chamber. It sends the fluid collected due to small leakage to the tank
and thereby prevents the failure of the valve.

Fig : Pressure Relief Valve

Working Principle:
In the working of a relief valve, excessive pressurized fluid is provided
from an open path to a tank with the purpose of reducing work port pressure.
As soon as the fluid pressure begins to rise, the force is applied to the bottom
of the spool or poppet. This allows the valve to open modestly at first,

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bleeding a little fluid as required to maintain the downstream pressure. But
if the downstream pressure continues to rise, the force acting upon the
poppet or spool will be pushing it further towards the spring until the point
spring force is balanced by the hydraulic force .

Advantages
 A relief valve is a safety device that is used to prevent over
pressurization in a system.
 Relief valves are used in a variety of applications, including boiler
systems, pressure vessels, and piping systems.
 Relief valves are designed to open at a predetermined pressure in
order to release excess pressure from the system.
 Relief valves can be either manually operated or automatically
operated.
 Relief valves are an important safety feature in many industrial and
commercial applications.

Disadvantages
The disadvantages of this valve include opening and closing not being
prompt, a large space is required when assembling, starting, and maintaining
it. It is also prone to leakage when operated at high temperatures due to
periodical fluctuations. The pressure control valve also creates vibration.

2. Unloading Valve:
This valve consists of a control chamber with an adjustable spring which
pushes the spool down.
The valve has two ports one is connected to the tank and another is
connected to the pump. The valve is operated by movement of the spool.
Normally, the valve is closed and the tank port is also closed.
These valves are used to permit a pump to operate at the minimum load. It
works on the same principle as direct control valve that the pump delivery is
diverted to the tank when sufficient pilot pressure is applied to move the
spool. The pilot pressure maintains a static pressure to hold the valve

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opened. The pilot pressure holds the valve until the pump delivery is needed
in the system.
As the pressure is needed in the hydraulic circuit; the pilot pressure is
relaxed and the spool moves down due to the self-weight and the spring
force. Now, the flow is diverted to the hydraulic circuit.

Working Principle:
In an unloading valve, a force is exerted on the valve by the spring, so the
valve will stay closed. The valve spool will shift only if the external force is
greater than the spring force. The external force will act on the opposite side
of the valve spool. Hence, when the valve spool will shift then the output will
be diverted.

When the cylinder reaches the end of the extension stroke, then the
unloading valve will open. High-pressure oil is present in the pilot of the
unloading valve. When the cylinder retracts, the pressure in the pilot of the
unloading valve will reduce because of the motion of the piston. So, at this
point, the unloading valve will be reset till the cylinder retraction. And at this
time, the pump will be unloaded by the unloading valve. The unloading valve
will unload the pump after the retraction strokes.

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Advantages
The heating of oil can be avoided by recirculating with a second
pump in the circuit. Less energy is consumed. Due to the use of unloading
valves, smaller and less expensive directional control valves can be used. At
the same time, the pressure drop can also be kept low .

Disadvantages
Temperature fluctuations can have a negative effect on hydraulic
valve systems. Oil is prone to ambient temperature, and fast heat loss or gain
can cause changes in oil viscosity, affecting the operation of the hydraulic
components.

3. Pressure Reducing Valve:

Sometimes a part of the system may need a lower pressure. This can be made
possible by using pressure reducing valve. These valves are used to limit the
outlet pressure.
Generally, they are used for the operation of branch circuits where the
pressure may vary from the main hydraulic pressure lines.
These are open type valve and have a spring chamber with an adjustable
spring, a movable spool as shown in figure. A drain is provided to return the
leaked fluid in the spring (control) chamber. − A free flow passage is provided
from inlet port to the outlet port until a signal from the outlet port tends to
throttle the passage through the valve. The pilot pressure opposes the spring
force and when both are balanced, the downstream is controlled at the
pressure setting.

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 Fig. Pressure Reducing Valve Working

Working Principle:
When the pressure iii the system is less than the pre-set value of spring
force, free flow of fluid takes place from the inlet port to the outlet port
without any restriction. If the downstream pressure reaches to time pre- set
value, time the control signal line transmits the output pressure to time
spool. Then, spool moves upwards against the spring force amid closes the
outlet port partially. Due to this, flow rate of fluid gets reduced, thereby by
the downstream pressure will decrease to a value below the valve setting. If
the spring is completely closed, time fluid leaks into spring chamber past the
spool and then drained to down- stream, which leads to raise in pressure of
downstream above pre-set valve. Thus, it is avoided, as time fluid is drained
continuously to time tank.

Advantages
1. It provides stable fluid pressure in the system.
2. By attaching a check valve, it allows free flow in the reverse direction.
3. Throttling noise is less.
4. Less maintenance.

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Disadvantages
There are two main causes for your pressure reducing valve to fail due to
controlled excess pressure under normal load conditions: Dirt or foreign
material has got between the pilot valve seat and the head

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 Lab Report - 4
AIM: To study Flow Control Valves generally used in oil hydraulics/pneumatic
FLOW CONTROL VALVE
Theory
The flow control valve is a critical component in fluid control systems, allowing
precise regulation of flow rates for different applications. This lab report aims to
explore the working principle of a needle valve, a common type of flow control
valve. A needle valve operates based on flow resistance, making it ideal for
applications requiring accurate flow adjustments.
TYPES
1. Needle Valve: A type of valve with a tapered, needle-like point that can
precisely regulate flow rates by adjusting the position of the needle within
the valve.

2. Globe Valve: A valve with a movable disk or plug that can control flow by
varying the size of the flow passage.

3. Ball Valve: Uses a rotating ball with a bore to control flow. It can be fully
open or fully closed, allowing for fast shutoff.

4. Butterfly Valve: A disc-shaped valve that rotates to control flow by either

fully opening or closing the flow passage.

5. Gate Valve: A valve with a sliding gate that moves perpendicular to the
flow direction to control flow.

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WORKING PRINCIPLE:

-Flow control valves work on the principle of restricting the flow area to
control the flow rate of fluids.

- A common type, the needle valve, adjusts a tapered needle within the
valve body to change the effective flow area.

- By rotating the needle, the flow rate can be either increased or decreased.

- Moving the needle closer to the valve seat restricts the flow and reduces
the flow rate.

- Moving the needle away from the seat increases the flow area, allowing
for higher flow rates.

- Flow control valves provide precise flow regulation, making them

suitable for applications requiring accurate flow management.

Page | 25
Working Procedure:

1. Ensure the needle valve is in the closed position by turning the valve
stem fully clockwise.

2. Connect the fluid supply to the inlet port of the valve and the outlet port
to a flowmeter or downstream apparatus.

3. Gradually open the needle valve by turning the valve stem counter
clockwise to the desired position.

4. Observe the flowmeter readings or downstream effects to determine the

flow rate and adjust as needed.

5. Record the corresponding flow rate at different valve stem positions to

analyze the valve's flow control capability.

Page | 26
Advantages of Flow Control Valves:

1. Precise Flow Regulation: Flow control valves can provide accurate and
precise control over flow rates, making them suitable for applications
where precise flow management is essential.

2. Versatility: These valves are used in various industries and applications,

including hydraulic systems, water treatment, chemical processing, and
more.

3. Shutoff Capability: Some flow control valves, like ball valves, can
completely shut off the flow, providing excellent isolation when needed.

4. Easy Installation: Flow control valves are generally easy to install and
integrate into existing systems.

Disadvantages of Flow Control Valves:

1. Pressure Drop: Flow control valves may create pressure drops across
the valve, leading to reduced system efficiency.

2. Sensitivity to Contaminants: Fine clearances in needle valves can be

sensitive to contaminants, potentially leading to clogging or damage.

3. Mechanical Complexity: Certain types of flow control valves,

especially those with advanced features like proportional control, can
be mechanically complex. This complexity may increase maintenance
requirements and the risk of potential failures.

4. Size and Weight: Flow control valves, especially those designed for
high flow rates and pressures, can be relatively large and heavy. This
size and weight can impact the overall system design and installation.

Page | 27
5. Heat Generation: During flow regulation, energy is dissipated as heat
due to the pressure drop across the valve. In some applications, this heat
generation can be a concern and may require additional cooling
measures.

Applications of Flow Control Valves:

Flow control valves find applications in various industries, such as:

Hydraulic Systems: Used to control the speed of actuators in hydraulic

machinery.

Water Management: Flow control valves are used in water distribution

systems to regulate water flow.

Oil & Gas: Used in the oil and gas industry to control fluid flow in
pipelines and equipment.

Chemical Processing: Flow control valves are essential for precise

control of chemicals in various processes.

HVAC Systems: Used to regulate the flow of fluids in heating,

ventilation, and air conditioning systems.

Pneumatic Systems: Used to control airflow in pneumatic circuits.

It's important to note that the specific type of flow control valve chosen
depends on the application's requirements and the characteristics of the
fluid being controlled.

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 Lab report – 5
AIM: Study of direction control valves generally used in oil hydraulic /
pneumatic System.

Directional Control Valves (DCVs):

Directional control valves (DCVs) are one of the most
fundamental parts in pneumatic and hydraulic systems. Directional control
valves are designed to control the direction of the flow of fluid.
They usually consist of a piston inside a cylinder which is electrically
controlled. The movement of the cylinder restricts or permits the flow, thus
it control the fluid flow.
Directional control valves for hydraulic and pneumatic systems are similar
in design and operation. However, there is one major difference. The return
port of a hydraulic valve is ported through a return line to the reservoir,
while the similar port of a pneumatic valve is usually line to the reservoir,
while the similar port of a pneumatic valve is usually vented to the
atmosphere.

How directional control valves are classified:

 According to the port type: -
1. Two-way valves
2. Three-way valves
3. Four-way valves
4. Five- way valves
 According to the method of actuation:-
1. Manually
2. Mechanically
3. Solenoid
4. Hydraulic
5. Pneumatic
 According to the internal moving part construction:-
1. Poppet type
2. Rotary type
3. Sliding spool

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  According to the fluid path:-
1. Check valve
2. Shuttle valve

WORKING PRINCIPLE:
1. TWO-WAY DIRECTION CONTROL VALVES:-
A 2-way directional valve has two ports normally called inlet and
outlet. When the inlet is blocked in the at-rest condition, it is referred to
as “normally closed” (NC). The at-rest box or the normal condition is the
one with the flow lines going to and from it.

2. THREE-WAY DIRECTION CONTROL VALVES (3/2 DCV):-

When a valve has one pressure port, one tank port and one actuating
port, it is known as three way valve.
In this valve, the pressure port pressurizes one port and exhausts
another one. Only one actuator port is opened at a time.
In some cases a neutral position is also available when both the ports
are blocked. Generally, these valves are used to operate single acting
cylinders.

Fig.—3/2 DCV

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3. FOUR-WAY DIRECTION CONTROL VALVES(4/2 DCV):-
In a four way, two position valves there are four inlet/outlet ports
in the valve and the spool can be located in one of two positions.
For 4/2 valve fluid is always flowing through the valve with system
pressure supplied to one of the two outlet ports at all times. The other
port would then be ported to return.
4/2 valves would normally be used in hydraulic systems in
conjunction with an upstream shut valve (or 2/2 valve).

4. 4/3 WAY DC VALVES:-

The 4/3 directional valve means that the block has 4 holes and the spool
3 positions.

The spool moves when the coils are energized (items 5 and 6). It
resumes its initial position thanks to the return springs (items 10 and
11) located on each side of the spool.

At rest the spool is closed (P, T, A, B closed).

Fig.—4/3 DCV

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5. FIVE- WAY DIRECTION CONTROL VALVES(5/2 DCV):-
A 5/2-way valve has five ports and two states. These valves are used
for instance to control double acting cylinders. A double acting cylinder
requires two outlet ports of the valve. 5/2-way valves can be mono-stable
or bi-stable.

Fig.---5/2 DCV

6. 5/3 WAY DC VALVES:-

The before mentioned valves all have two states. It is also possible
to have a third state, for example, a 5/3-way solenoid valve. The third
state is used to stop a double acting cylinder in an intermediate position.
These valves are mono stable and return to the center position when the
solenoids are not energized. Two solenoids are used to switch the valve
to the other two states. 5/3 valves are available in three variants; with
closed center position, with venting center position and with the
pressurized center position. The closed center valve is represented by the
symbol shown below.

Fig.—5/3 DCV

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7. POPPET TYPE DC VALVES:-
The poppet could also be a ball or simple discs, cones similar item like
a plate used in conjunction with simple valve seats to control flow.
They are made to sit over a specially constructed, finely machined, and
polished seat.

Large capacity valves need large valve seat areas, resulting in large
operating force.

The high pressure in

hydraulic systems thus
tends to present the use
of simple poppet valves
and they are, therefore,
predominantly found in
the low-
pressure pneumatic
systems.

Fig.—Poppet type DCV

8. ROTARY TYPES DC VALVES:-

A lever operated rotary type directional control valve is generally
used for high pressure applications. It works
on the shear seal principle which gives good
sealing and zero leakage. These valves are
used where leak-free closure is required.

9. SLIDING SPOOL DC VALVES:-

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 The sliding spool two-way directional control valve is operationally
similar to the three, four-way valve. The sliding spool valve is so named
because of the shape of the valve element. In the housing, it slides back
and forth to cover and uncovers the ports. The sliding element is also
referred to as a piston or spool.

VALVE ACTUATION :
TYPES OF VALVE ACTUATION:
1. Manual actuation:- In this type, the spool is operated manually. Manual
actuators are hand lever, push button and pedals etc.
2. Mechanical actuation:- The DCV spool can be operated by using
mechanical elements such as roller and cam, roller and plunger and rack
and pinion etc. In these arrangements, the spool end is of roller or a
pinion gear type. The plunger or cam or rack gear is attached to the
actuator. Thus, the mechanical elements gain some motion relative to
the actuator (cylinder piston) which can be used for the actuation.
3. Solenoid actuation:- The solenoid actuation is also known as electrical
actuation. The schematic of solenoid actuation is shown in Figure 2.21.
The energized solenoid coil creates a magnetic force which pulls the
armature into the coil. This movement of armature controls the spool
position. The main advantage of solenoid actuation is its less switching
time.

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 4. Hydraulic actuation:- This type actuation is usually known as pilot-
actuated valve and a schematic is shown in Figure 2.22. In this type of
actuation, the hydraulic pressure is directly applied on the spool. The
pilot port is located on one end of the valve. Fluid entering from pilot
port operates against the piston and forces the spool to move forward.
The needle valve is used to control the speed of the actuation.
5. Pneumatic actuation:- DCV can also be operated by applying
compressed air against a piston at either end of the valve spool. The
construction of the system is similar to the hydraulic actuation as shown
in Figure 2.22. The only difference would be the actuation medium. The
actuation medium is the compressed air in pneumatic actuation system.

SPECIFICATION OF DC VALVES:
 Max Flow (L/Min) : 80 to 120
 Fluid Temperature (°C) : -20~70
 Viscosity (mm² /s) : 2.8 ~ 100
 Working Voltage : (V) DC, 12, 24, AC, 110V/50Hz, 220V/50Hz
 Maximum Switch Frequency (T/H) : 15000 (DC) 7200 (AC)
 Insulation Grade : IP65
 Weight (kg): Single Solenoid 1.45 (DC) 1.4 (AC), 5.1 (DC): 4.3 (AC),
Double Solenoid 1.95 (DC): 1.9 (AC) 6.7 (DC) 5.1 (AC)

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SYMBOL OF DC VALVES:-

APPLICATION OF DC VALVES:-
 Control valves are applied in each area where hydraulic
control and actuation tasks occur.
 In the automotive area, Supply, control and regulating of
actuations for automated manual transmissions (AMT),
double clutch transmissions (DCT), continuous variable
automatic transmissions (CVT) or automatic transmissions
(AT).
 Control of automated clutch actuations in hybrid drives.
 Control of differential locks.

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