COVER PAGE

UNIT II

DESIGN OF HYDRAULIC AND PNEUMATIC SYSTEMS

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 Unit II

Topics

2.1 Hydraulic Actuators

2.2 Hydraulic Cushioning

2.3 Cylinder Mounting

2.4 Gear Motors

2.5 Control Valves

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 OMR352 HYDRAULICS AND PNEUMATICS LT PC 3 0 0 3

UNIT II

DESIGN OF HYDRAULIC AND PNEUMATIC SYSTEMS

Hydraulic Actuators: Cylinders – Types and construction, Application, Hydraulic cushioning

– Hydraulic motors - Control Components: Direction Control, Flow control and pressure
control valves – Types, Construction and Operation – Servo and Proportional valves.
Course Outcomes
CO1: Analyze the methods in fluid power principles and working of hydraulic
pumps
Course Objectives
To knowledge on fluid power principles and working of hydraulic pumps

Important Topics

2.1 Hydraulic Actuators

2.2 Hydraulic Cushioning

2.4 Gear Motors

2.5 Control Valves

2.1 Hydraulic Actuators:

Actuators are the devices used for converting hydraulic energy into mechanical energy.

• In other words, actuators perform a function just opposite to that of the pumps.

• The pressurized hydraulic fluid delivered by the hydraulic pump is supplied to the actuators,
which converts the energy of the fluid into mechanical energy. This mechanical energy is
used to get the work done:

• The hydraulic actuators produce linear, rotary, or oscillating motion.

• They can be used for lifting, tilting, clamping, opening, closing, metering, mixing, turning,
swinging, counterbalancing, bending and for many other operations.
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 • Special applications are on roll-over devices, conveyors, valve operators, printing presses,
rock drills, dies, clamps, machine tools, etc.

2.1.1. Types of Hydraulic Actuators

Based on the type of motion actuators produce, they are categorized into two :

1. Linear actuators (also called 'hydraulic cylinders'), and

2. Rotary actuators (also called 'hydraulic motors').

(a) Continuous rotary actuators (or simply hydraulic motors), and

(b) Limited-rotation rotary actuators (also called 'oscillation fluid motors').

The linear actuators generate motion in a straight line to perform the work. The rotary
actuators generate rotary output motion to perform the work.

2.1.1.2. LINEAR ACTUATORS

LINEAR ACTUATORS (OR HYDRAULIC CYLINDERS)

• A linear actuator or hydraulic cylinder is a fluid motor that generates linear motion. In other
words, hydraulic cylinder is a device which converts fluid power into linear mechanical force
and motion.

• The hydraulic cylinders are basically used for performing work such as pushing, pulling,
tilting, and pressing in a variety of engineering applications such as in material handling
equipment, machine tools, construction equipment, and automobiles.

Types of Hydraulic Cylinders

The linear hydraulic cylinders can be classified into many types based on various criteria.
Some of them are given below:

1. Based on the cylinder action:

(a) Single-acting cylinders, and

(b) Double-acting cylinders.

2. Based on the cylinders' design:

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 (a) Plunger or ram cylinders,

(b) Telescoping cylinders,

(c) Tandem cylinders,

(d) Cable cylinders,

(e) Diaphragm cylinders,

(f) Bellow cylinders,

(g) Duplex cylinders, etc.

3. Based on the cushioning feature:

(a) Cushioned type hydraulic cylinders, and

(b) Non-cushioned type cylinders.

4. Based on the piston or plunger used:

(a) Piston type cylinders, and

(b) Plunger type cylinders.

5. Based on the cylinders' movement:

(a) Rotating type cylinders, and

(b) Non-rotating type cylinders.

However, we shall present only few important basic hydraulic cylinders in the following
sections.

2.1.3.1. SINGLE-ACTING CYLINDERS

• As the name suggests, single-acting cylinders can deliver a force in only one direction.

• The single-acting cylinder is the simplest type of all hydraulic cylinders.

2. Construction

Single-acting cylinder has only one port at one end of the cylinder barrel to allow the
hydraulic fluid. The schematic representation of a single-acting cylinder is depicted in
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 Fig.5.1(a). Fig.5.1(b) show its symbolic representation. It is designed in such a way that the
extending movement is forced by hydraulic fluid and the piston is retracted by gravity or a
compression spring.

compression spring.

The piston is assembled inside a cylindrical housing called barrel. To maintain the close
fitting between the piston and barrel, piston seal is attached at the circumference of the
piston. A rod is connected to the piston and extended out of the barrel to deliver the force. At
the other end of the barrel, there is a port for the fluid.

3. Operation

During the extending action, the force is applied by the pressurized fluid. The force applied to
a piston depends on both the area of the piston and the pressure of the fluid.

In single-acting cylinders, pistons do not retract hydraulically. But the retraction is

accomplished by using gravity or by using the compression spring as shown in Figure. If a
cylinder is employed to lift a load, then the load itself can retract the piston.

4. Advantages and Disadvantages of Single-Acting Cylinders

• Advantages: The single-acting cylinders are very simple to operate, and compact in size.

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 • Disadvantages: The single-acting cylinders with spring return cannot be used for larger
stroke lengths.

2.1.3.2.DOUBLE-ACTING CYLINDERS

• In double-acting hydraulic cylinders, liquid pressure can be applied to either side of the
piston, thereby providing a hydraulic force in both directions.

• The double-acting cylinders are mostly used in applications where larger stroke lengths are
desired.

2. Construction

Figure shows the construction of a double-acting cylinder

The five basic parts of the double-acting cylinders are:

1. Base cap with port connections,

2. Bearing cap with port connections,

3. Cylinder barrel,

4. Piston, and

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 5. Piston rod.

The components are designed in such a way that the end caps and pistons are common to all
cylinders of the same diameter, and only barrels and piston rods need to be changed to
construct different length cylinders. The end caps are welded to the barrel and the piston rods
are threaded to the piston.

In order to prevent wear and leakage, the inner surface of the barrels must be made very
smooth. Usually, a seamless drawn steel tube is used as a barrel. The cast iron or steel piston
is used to transmit force to the piston rod. Also, the piston acts as a sliding bearing in the
barrel and provide a seal between high- and low-pressure sides. Piston seals are provided in
between piston and barrel to avoid any leakage. The piston rods are usually made of heat-
treated chromium alloy to protect it from corrosion and abrasion.

A wiper or scraper seal is fitted on the outside of the piston rod bearing to prevent grit,
water or other matter being drawn into the bearing. An internal sealing rings (also called O
rings) are fitted behind the bearing to prevent high pressure fluid leaking out along the rod.
The end caps have threaded entries for the ports.

3. Operation

During the extension stroke, the pressurized fluid (usually from the pump) enters through
extend port. This fluid moves the piston towards left and the fluid present on the other side is
pushed out to the reservoir from the cylinder through retract port.

During the retraction stroke, the fluid is allowed to enter the cylinder through retract port and
the piston moves towards right and the fluid present on the other side is pushed out to the
reservoir from the cylinder through extend port.

It can be seen from Figure that the volume on both the sides of the piston are different. Since
the piston rod is attached at one side only, the cylinder exerts greater force when extending [F
= P × Apiston] than when retraction [F = P × (Apiston - Arod)]. This results in different pressure
levels on either side of the piston and that's why double-acting cylinders are also called as
differential cylinders.

Thus the both extension and retraction strokes of the double-acting cylinder provide a linear
output motion which can be used to accomplish some useful work.

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 2.1 CYLINDER CUSHIONING
• When the pressurised fluid is allowed to enter inside the cylinder, the piston accelerates and
travels in the cylinder barrel. If the piston is allowed to travel at the same speed till the end of
the stroke, it will hit the end cap with a great impact. To avoid this impact, the piston needs to
decelerate at the end of the travel. The arrangement made at the end caps to achieve the same
is called 'cylinder cushion’.

• In other words, the cylinder cushioning slows down and prevents impact at the end of a
piston stroke (by gradually decelerating the piston speed from start of stroke to the end of
stroke).

2. Construction and Operation

A typical cylinder cushioning arrangement is illustrated in Fig.5.3. Figs.5.3(a) and (b) show
the position of the piston at the start and of the cushioning action, respectively.

As the piston approaches the end of its stroke, the plunger enters the end cap port and thus
blocks the free flow. Now the fluid is trapped between the piston and the end cap. This fluid,
can escape only by passing through the adjustable restrictor, as shown in Fig.5.3(b). This
fluid flow through the restricted flow path causes the piston to decelerate. The rate of
deceleration of the piston can be controlled by the adjustable needle valve. A non-return or
check valve is provided to allow free flow of fluid to the cylinder quickly during the return
stroke.

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 2.1.2. SPECIAL HYDRAULIC CYLINDERS

2.1.2.1. TELESCOPIC CYLINDER

• Telescopic cylinder is used where there is a space constraint.

• A telescopic cylinder consists of a series of rams nested in a telescopic assembly which

provide a long extension.

• Such cylinders are useful for applications requiring a long stroke but with only limited
space available for the unextended ram.

• Some of the applications of telescopic cylinders include hydraulic cranes, high-lift fork
trucks, dump trucks, dipper wagons, etc.

2. Construction and Operation

Figure illustrates the arrangement of a typical telescoping type cylinder having three rams.

Since the diameter A of the ram is relatively large, this ram produces a large force for the
beginning of the lift of the load. When ram A reaches the end of the stroke, ram B begins to
move. Now ram B provides the required smaller force to continue raising the load. When ram

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 • In many fluid power applications, the greatest force is required to begin lifting the load.
Once the lifting of load has started, then the required force to continue raising the load will be
smaller.

B reaches the end of its stroke, then ram C moves outwards to complete the lifting operation.
These three rams can be retracted by gravity acting on the load or by pressurized fluid acting
on the lip of each ram.

3. Working of a Two-Stage Double-Acting Telescopic Cylinder

Figure illustrate the operation of a typical two-stage double-acting telescopic cylinder.

Retraction stroke: During the retraction stroke, the fluid is fed into the first-stage annulus
via retract port A. Therefore, the first stage piston is forced to the left until it uncovers the
fluid ports connecting this with the second stage annulus. This, in turn, moves the larger
piston to the left until both the pistons are fully retracted into the body of the cylinder.

Extension stroke: During the extension stroke, the fluid is fed through the extend port B.
Now the fluid forces both pistons to the right until the cylinder is fully extended.

As could be seen from Figure that many seals are provided for preventing any possible fluid
leakages.

2.1.2.2. TANDEM CYLINDERS

• A tandem cylinder is one in which two or more piston and rod combinations are assembled
as a rigid unit with all pistons mounted on single rod.

• Such cylinders are designed to provide a large working area and thus large forces for a
given pressure for a small cylinder diameter.

• These cylinders are used to obtain a low-force, high-speed action followed by a high- force,
low-speed action.

2. Construction and Operation

Figure illustrates a stepped-tandem cylinder, in which two pistons of different sizes mounted
on one rod. It contains two cylinders that slide inside each other. Since two cylinders are
arranged in series, the tandem cylinder produces the large force (almost double). However, its
drawback is that they occupy more linear space.
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 3. Dual Linear Actuator

Another modification of tandem cylinders is the dual cylinder designs. A dual linear actuator
is shown in Figure. The piston and rod assemblies of a dual actuator are not fastened together
as in the tandem actuator. In most dual actuator designs, a given piston acts on another only
in one direction.

2.1.2.3. DOUBLE-ROD AND RODLESS CYLINDERS

1. Double-Rod Cylinder (or Through Rod Cylinder)

• A double-rod cylinder, also known as through rod cylinder, has piston rods extending
from both ends of the cylinder.

• Fig.5.8 illustrates a double-rod cylinder.

• These cylinders produce equal force and speed on both sides of the cylinder.

2. Rodless Cylinder

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 • As the name implies, a rodless cylinder has no piston rod, being constructed with a slide
table assembly mounted directly above the piston. The table and piston are connected either
directly, using a slot cut along the top of the cylinder body, or indirectly, through magnets
located on both the piston and table.

• Rodless cylinders are being developed to overcome the space limitations of conventional
actuators. They provide relatively compact, space saving devices, capable of moving or
positioning components or tools in assembly and automation systems.

• Typical applications include assembly automation, packaging, electronics, etc.

2.3. CYLINDER MOUNTINGS

• The hydraulic cylinders are to be mounted properly depending upon their applications for
which they are designed. Improper mounting can cause side loading, which destroys rod
bearings and seals, or loosens hydraulic connections to cause leaks. In the worst cases, it can
even cause pistons to bind or rods to buckle.

• Some of the factors to be considered while selecting a particular mounting are nature of
applications, type of force applied (tensile/compressive/bucking load), alignment of the rod
with the resistive load, space constraints, etc.

2. Types of Cylinder Mountings (Methods of Cylinder Mountings)

In order to accommodate a wide variety of applications, there are different type of cylinder
mountings are available. Five important types of mountings normally used in industries are
depicted in Fig.5.9.

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 1. Foot mounting: It should be designed to give a limited amount of movement on one foot
only to allow for thermal or load expansion. That is, the cylinder should be positively located
or dowelled at one end only (Fig.5.9(a)).

2. Rod-end flange or front flange mounting: During the extend stroke, pressure in the
hydraulic fluid acts on the cylinder-end cap, the force set up being transmitted to the front
mounting flange through the cylinder body (Fig.5.9(b)).

3. Rear flange, back flange or head-end flange mounting: No stress is present in the
cylinder owing to load on the extend stroke; only hoop stress is present. The load acts
through the fluid onto the rear flange (Fig.5.9(c)).

4. Trunnion mounting: It allows angular movement. It is designed to take shear load only.
Bearing should be as close to the cylinder body as possible (Fig.5.9(d)).

5. Eye or clevis mounting: There is a tendency for the cylinder to jack knife under load. Side
loading of bearing must be carefully considered (Fig.5.9(e)).

3. Engine Mounting Arrangements

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 A typical engine mounting arrangements are

2.4 ROTARY ACTUATORS (OR HYDRAULIC MOTORS)

• The function of a rotary actuator is to convert hydraulic energy into rotary mechanical
energy.

• Rotary actuators are the hydraulic equivalents of electric motors. Hence_rotary actuators are
also called as hydraulic motors.

• The hydraulic motors are very much identical in construction and size to rotary type pumps.
They work on exactly the reverse principle to that of rotary pumps.

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 • Instead of pushing the fluid as pumps do, in a hydraulic motor the rotating elements (ie.,
vanes, gears, pistons, etc.) are pushed by the pressurized fluid. This enables the hydraulic
motor to develop the necessary output torque and rotating motion.

• The hydraulic motors are usually rated/specified in terms of the torque developing capacity
or differential pressure.

2. Classification of Hydraulic Motors

The hydraulic motors can be classified based on their degree of angular movement as :

1. Continuous rotary hydraulic motors, and

(i) Gear motors, (ii) Vane motors, and (iii) Piston motors.

2. Limited-rotation hydraulic motors*

(i) Vane type, and (ii) Piston type.

Now we shall discuss the construction and operation of gear, vane, and piston motors, in the
following sections.

2.4.1. GEAR MOTORS

• Like gear pumps, gear motors are fixed displacement devices.

• Also, gear motors can be classified as external or internal gear units.

• External gear motors include the gear-on-gear units such as the spur gear motor.

• Internal gear motors include the crescent seal types and the gerotor type unit.

2. Construction and Operation

Figure illustrates the operation of a gear motor. In this type, both the gear wheels are driven
and one of the gear wheel has an extended shaft to provide output torque.

In the gear motor, rotary motion is produced by the unbalanced hydraulic forces on the gear
teeth. The hydraulic imbalance in a gear motor is caused by gear teeth unmeshing. As gear
teeth unmesh, all teeth subjected to system pressure are hydraulically balanced, except for
one side of one tooth on one gear. This imbalance of force on gears, as shown in Fig.5.11,

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 develops the torque. It should be noted that the larger the gear tooth or higher the pressure,
more is the torque produced.

• These motors provide rotary output motion over a finite angle. That is, the rotation of the
shaft of these motors is less than 360°. (Usually 90°, 180°, or 270°).

3. Advantages of Gear Motors

The gear motors are simple in design, and very cheap in cost.

4. Disadvantages of Gear Motors

(i) Gear motors are subjected to relatively high internal leakage. Therefore, they are not
suitable for high torque, low speed applications.

(ii) The high pressure at the inlet, coupled with the low pressure at the outlet, generates very
high bearing loads.

5. Ranges

The gear motors are available for peak operating pressures upto about 125 bars, with rated
capacities upto 10 Lps, and maximum speeds of about 3000 rpm.

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 2.4.2. VANE MOTORS

1. What are Vane Motors?

• Vane motors work on the same principle as vane pumps in reverse.

• In these motors, the pressurised fluid acting on the vanes causes them to rotate and thus
developing the torque output.

• They are suitable for low speed applications than gear motors.

2. Construction and Operation

Like vane pumps, vane motors can be classified as unbalanced or balanced vane motors. But
most vane motors used universally are of the balanced-rotor type. Because hydraulic
unbalance causes large radial bearing loads which limit the use of unbalanced vane motors to
low pressure operation. Therefore most vane motors have a mechanical configuration similar
to that of the balanced vane pump. Also balanced vane motors are fixed-displacement units.

Fig.5.12 illustrates the construction and operation of a balanced-type vane motor.

The vane motor produces torque by the hydraulic pressure that acts on 'the exposed surfaces
of the vanes, which slide in and out of the rotor connected to the driver shaft. To

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 accommodate starting and low-speed operation, it is usually necessary to provide a force, in
addition to the centrifugal force, to move the vane radially outward. Springs are commonly
used for this purpose. The larger the exposed area of the vane, or higher the pressure, more is
the torque developed. Also, as the inlet connects to two opposing pressure passages, the side
loads on the rotor are balanced with each other (Fig.5.12(b)).

3. Advantages of Vane Motors

The vane motors have relatively less internal leakage than gear motors. Also the balanced
vane motors eliminate the side and bearing loads.

4. Disadvantages of Vane Motors

Vane type motors, like gear motors, do not generate maximum torque at very low speeds, due
to internal leakage. So both gear and vane type motors are not suitable for vehicle drive
applications.

5. Ranges

Vane motors are available at pressure ratings to about 175 bars, with rated capacities upto 15
Lps, and at speeds up to 4000 rpm.

2.4.3. PISTON MOTORS

• Piston motors are positive displacement motors which can develop an output torque at the
shaft by allowing pressurised fluid to act on the pistons.

• The piston motors can be either fixed or variable-displacement devices.

• They are suitable for low speed, high torque traction applications such as earth-moving
machinery, agricultural tractors, railway locomotive and other industrial applications.

• The piston motors are the most efficient and can operate at the highest speeds and pressures,
when compared to gear and vane type motors.

• Types: Piston motors can be classified in terms of the piston motion as :

1. Axial-piston motors, and

2. Radial-piston motors.

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 2. Axial Type Piston Motors

Construction and Operation : The operation of an axial type piston motor is essentially the
same as that of an axial piston pump except for the direction of flow (refer Section 4.17, and
Fig.4.15)

The pressurised liquid introduced through the motor inlet forces the piston assembly against
the thrust cam or swash/wobble plate. The angular application of this force causes the plate to
rotate and this rotation is transmitted by the shaft. The displacement can be varied by
changing the angle of the thrust cam.

3. Radial Type Piston Motors

Construction and Operation: The operation of a radial type piston is also essentially the
same as that of an radial piston pump except for the direction of flow (refer Section 4.19 and
Fig.4.21). Fluid enters the piston chamber through a central eccentric cam. The piston is
forced radially outward against the thrust ring, thereby producing a force tangent to the piston
chamber. The resulting torque causes the shaft to rotate.

4. Advantages of Piston Motors

(i) The piston motors exhibit very high volumetric efficiencies.

(ii) They produce very high torque.

(iii) They are capable of working at very high pressures and speeds.

(iv) They are available in both fixed and variable type displacement units.

5. Disadvantages of Piston Motors

(i) The cost per horse power is relatively high.

(ii) The power-to-weight ratio of piston motors are comparatively less as that of gear and
vane motors.

6. Ranges

The piston motors are available at pressure ratings upto 350 bars with rated capacities upto 30
Lps and at operating speeds of 12,000 rpm.

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 LIMITED-ROTATION HYDRAULIC MOTORS

1. What are Limited-Rotation Hydraulic Motors?

• The limited-rotation motors provide an oscillating power output. In other words, limited-
rotation motors provide rotary output motion over a finite angle.

• Usually the rotation of the shaft of these motors is 90°, 180°, or 270°.

• Types: The two types of limited-rotation motors used to obtain an oscillatory output are:

1. Vane type limited-rotation motors, and

2. Piston type limited-rotation motors.

2. Vane Type Limited-Rotation Motors

There are two types of limited-rotation vane motors, the single-vane and the double-vane.
Fig.5.13 and 5.14 illustrate the operation of a typical single-vane and double-vane rotation
motors respectively. In both the single- and the double-vane units, seals are maintained
between the rotor and the barriers, and between the vanes and the housing.

1. Single-Vane Rotation Motor

As shown in Fig.5.13, the single-vane unit consists of a cylindrical housing, a shaft with a
single vane, a barrier which limits the vane rotation, and end pieces which support the shaft.

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 Pressurised liquid enters on the side of the vane, forcing the vane to rotate to the barrier. The
single-vane unit produce the rotation of approximately 280°.

2. Double-Vane Rotation Motor

In the double-vane unit, the pressurised fluid enters on one side of a vane and is ported
through the shaft to the corresponding side of the other vane, as shown in Fig.5.14. A rotation
of about 100° can be obtained with the double-vane unit.

3.Ranges

The limited-rotation vane motors are available with torque output ranging from less than 1 N-
m at 4 bars to nearly 85 kN-m at 200 bars.

3. Piston Type Limited-Rotation Motors

Fig.5.15 illustrates a typical piston type limited-rotation motor called helix-spline rotary
motor.

As shown in Fig.5.15, the helix-spline unit employs a shaft with a helical screw which passes
through the piston. A guide rod prevents rotation of the piston. Also a self-locking helix angle
prevents rotation when an external torque is applied. This type of motors can obtain any
desired rotation angle. Both lesser and greater than 360° are possible.

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 2.5. DIRECTIONAL CONTROL VALVES

These valves are used to control the direction of flow in a hydraulic circuit. According to the
construction of internal moving parts it is classified as poppet type and sliding spool type. It
may be further classified as one way, two way, three way and four way valves, depending
upon the number of port connections available. On the basis of actuating devices, it can be
classified as manually operated, mechanically operated, solenoid operated and pilot operated.

• CHECK VALVES

• PILOT OPERATED CHECK VALVE

• TWOWAY DIRECTIONAL CONTROL VALVE

• THREE WAY DIRECTION CONTROL VALVES

• FOUR WAY DIRECTIONAL CONTROL VALVES

2.5.1. CHECK VALVES

🔹 Definition:

A check valve is a type of non-return valve that allows fluid (hydraulic or pneumatic) to
flow in only one direction and prevents reverse flow automatically. It operates based on
pressure differential without the need for manual or external control.

🔹 Working Principle:

Check valves operate when the pressure on the inlet side exceeds the pressure on the outlet
side. A ball, poppet, disc, or piston inside the valve is pushed open by the fluid flow. If flow
attempts to reverse, backpressure forces the element against its seat, blocking the reverse
flow.

🔹 Types of Check Valves:

1. Ball Type Check Valve

2. Poppet Type Check Valve
3. Spring-Loaded Check Valve
4. Pilot-Operated Check Valve
5. Inline and Cartridge Type Check Valves

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 🔹 Functions & Applications:

 Prevent reverse flow in hydraulic lines

 Maintain pressure in part of a system (pressure holding)
 Used in hydraulic jacks, pumps, brake systems
 Isolation of subsystems

🔹 Advantages:

 Simple design and operation

 No manual intervention needed
 Prevents damage due to reverse flow
 Maintains pressure integrity in system branches

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 2.5.2. PILOT OPERATED CHECK VALVE

🔹 Definition:

A Pilot Operated Check Valve (POCV) is a modified form of a check valve that allows free
flow in one direction and blocks reverse flow unless a pilot pressure is applied. The pilot
pressure overrides the check valve mechanism, allowing reverse flow when required.

🔹 Working Principle:

 In normal operation, the valve allows flow in one direction (like a check valve).
 In reverse flow, the valve remains closed unless pilot pressure is applied at the pilot
port.
 The pilot pressure counteracts the spring or internal force holding the check closed,
opening it and allowing controlled reverse flow.

🔹 Construction:

 Main poppet/ball to stop reverse flow

 Pilot piston connected to a separate control port
 Spring-loaded mechanism
 Housing with inlet, outlet, and pilot ports

🔹 Functions:

 Prevents actuator movement due to external forces (e.g., load drop)

 Locks a cylinder in position under load
 Allows controlled release of pressure with pilot signal
 Prevents backdriving in systems with vertical loads

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 🔹 Applications:

1. Hydraulic Clamping Systems – Prevents clamp release unless a pilot signal is given.
2. Vertical Cylinder Locking – Holds cylinder load even if supply pressure fails.
3. Load Holding in Lifting Systems – Used in cranes, hoists, and lifting tables.
4. Double-acting Cylinder Control – Allows pressure-holding in one direction and
controlled motion in another.

2.5.3. TWOWAY DIRECTIONAL CONTROL VALVE

🔹 Definition:

A Two-Way Directional Control Valve (commonly called 2/2 DCV) is a valve that has two
ports and two switching positions. It is used to start or stop the flow of fluid (either
hydraulic oil or compressed air) in a single flow path.

🔹 Ports & Positions:

 Ports: Inlet (P) and Outlet (A)

 Positions:
1. Open Position: Flow is allowed from P to A.
2. Closed Position: Flow is blocked (no fluid transfer).

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 🔹 Operation Modes:

 Manually operated: Lever or push button

 Solenoid operated: Electrically controlled
 Pneumatically operated: Air pilot signals
 Mechanically operated: Cams or rollers

🔹 Functions of 2/2 DCV:

 Acts as an on/off switch in fluid power systems

 Used for start-stop control in actuators
 Functions as a safety shutoff valve
 Used in filling, clamping, and lifting operations

🔹 Applications:

1. Hydraulic Presses: To engage/disengage the press operation

2. Pneumatic Cylinders: Start/stop air flow
3. Lubrication Systems: Controlled fluid dispensing
4. Safety Interlock Systems: Stop motion when safety is breached

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 2.5.4. THREE WAY DIRECTION CONTROL VALVES

🔹 Definition:

A Three-Way Directional Control Valve (3/2 DCV) is a valve with three ports and two
positions. It is commonly used in single-acting actuators, allowing fluid to either enter or
exhaust from the actuator based on the valve position.

🔹 Ports and Positions:

 Ports:
o P – Pressure port (inlet)
o A – Actuator port (outlet)
o T (or R) – Tank/Exhaust port
 Positions:

1. Normal Position (de-energized): Port A connected to T → actuator is vented.

2. Actuated Position (energized): Port P connected to A → actuator extends.

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 🔹 Symbol:

Standard ISO symbol:

Actuated: P→A (flow to actuator)

De-actuated: A → T (actuator exhaust)

🔹 Modes of Operation:

 Solenoid actuated
 Pneumatically actuated
 Manually operated (lever/pushbutton)
 Spring return (default position)

🔹 Applications:

1. Single-acting cylinders – Used for extending and automatically retracting the piston.
2. Blow-off applications – Directing air to clean or blow debris.
3. Load release systems – Used to activate and deactivate mechanisms quickly.
4. Filling systems – Where brief, timed pressurization is needed.

🔹 Functionality:

 When energized, compressed air/oil flows from P to A to extend the actuator.

 When de-energized, the actuator port A is connected to exhaust (T) allowing return or
depressurization.

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 2.5.5. FOUR WAY DIRECTIONAL CONTROL VALVES

🔹 Definition:

A Four-Way Directional Control Valve is a valve that has four ports and two or three
positions, used to control the motion of double-acting cylinders or reversible hydraulic

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 motors. It can direct fluid flow to either side of the actuator and allow the opposite side to
return to tank or exhaust.

🔹 Ports Configuration:

 P – Pressure (supply) port

 A & B – Working (actuator) ports
 T (or R) – Tank/Return/Exhaust port

🔹 Types:

 4/2 DCV – 4 ports, 2 positions

 4/3 DCV – 4 ports, 3 positions (centered position varies)

🔹 Center Conditions in 4/3 Valves:

1. Closed Center: All ports blocked – holds cylinder position.

2. Open Center: All ports interconnected – no pressure build-up.
3. Tandem Center: A & B blocked; P connected to T – idle pump circulation.
4. Float Center: A & B connected to T; P blocked – motor/cylinder floats.

🔹 Symbol (4/2 example):

[P→A,B→T] (Position 1)
[P→B,A→T] (Position 2)

🔹 Operating Methods:

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  Solenoid operated
 Pneumatic pilot operated
 Manual lever or push-button
 Mechanical cam operated
 Spring return or detent type

🔹 Applications:

1. Double-acting cylinders – Forward and reverse movement

2. Hydraulic motors – Reversing rotation
3. Machine tools – Clamping, feeding, ejecting
4. Robotics & automation – Sequential motion control

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