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INTRODUCTION
In LAP 2 you learned to control the speed of actuators using a needle valve or by
feathering the DCV. You didn’t explore many details about how these techniques work,
you just used them. In this LAP, you will learn the details of why a needle valve or
feathering a DCV causes the flow rate to be reduced.
Also, in this LAP you will learn about two new valves: the flow control valve and the
check valve. You will then use these valves to design a number of circuits that control
actuator speed.
ITEMS NEEDED
Amatrol Supplied
1 85-BH Basic Hydraulic Training System
1 85-HPS Hydraulic Power Unit
School Supplied
1 Stopwatch
1 Allen Wrench Set
T T
T
P P
OUTLET ADJUSTER
BODY TO RESERVOIR
SYMBOL EXPLANATION
ADJUSTABLE
INLET OUTLET
NORMALLY
CLOSED
PILOT
TO OPEN
Almost all hydraulic systems have a relief valve in the circuit to act
as a safety device in case the pressure becomes too high. High pressure
can occur in a hydraulic system if the pump’s flow is blocked for some
reason.
The relief valve’s primary purpose is to limit system pressure during
normal operation as well as when a component malfunctions. During the
normal operation of a hydraulic system, the flow to the circuit will be
blocked for periods of time. This includes when the directional control
valve is in a blocked center condition, when a cylinder becomes extended
or retracted, or when an actuator is stalled by an excessive load.
Procedure Overview
In this procedure, you will connect a pilot-operated
relief valve to act as a safety device to limit the pressure in
the system whenever the pump’s flow is blocked by the
circuit. This skill will also show that the relief valve
performs this function several times during a normal cycle.
DRAIN
SUPPLY
LINE MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3
3
#1 #2
A A
NEEDLE
VALVE
A B
B B RETURN
MOTOR MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
SUPPLY GAGE
MANIFOLD A
IN A
OUT B
RELIEF
VALVE A DRAIN SMALL
BORE
3
1 CYLINDER
IN 2 OUT
RETURN
MANIFOLD
NOTE
When the cylinder is fully extended or retracted, hold the
DCV’s lever actuated while you make the flow and pressure
readings.
Cylinder extending
Cylinder extended
Cylinder retracting
Cylinder retracted
DCV centered
You should have observed that the relief valve opens when the
flow to the system is deadheaded or blocked. This occurs when the
cylinder is extended, retracted, or the DCV is centered.
Figure 7 shows what happens when the flow has been deadheaded
or blocked. The oil from the pump continues to flow into the
supply line even though it is blocked. As the pump continues to
push oil into the supply line, the oil pressure rises rapidly to 400
psi / 2070 kPa. Because 400 psi / 2070 kPa is the pressure setting
of relief valve A, it opens when the pressure at the inlet reaches a
pressure of 400 psi/2070 kPa and allows the flow to dump to the
reservoir, stopping the rise in pressure.
DCV
SHIFTED
GAGE A IN A
400psi / 2070kPa
RELIEF OUT B
VALVE A OIL FLOW IS
STOPPED
CYLINDER
FULLY
RETRACTED
M
Another application for the relief valve is to work with the needle
valve in controlling the speed of an actuator. This is accomplished by
restricting pump flow with the needle valve, increasing pressure to a
level that causes the relief valve to partially open and dump a part of the
pump’s flow. The remaining pump flow goes to the actuator. As a result,
the actuator moves at a slower speed.
EXTENDING
R B 540
3 GPM PSI 40
PSI
990
PSI
DCV
SHIFTED
2 GPM
M SET FOR
1000 PSI
5 GPM
Figure 8. Relief Valve Operating with a Needle Valve for Speed Control
This range of pressure between fully closed and fully open is usually
very small (i.e. 50 psi). When you set the relief valve pressure, you are
actually setting the full open pressure. This is when all flow is going
through the valve. But, the relief valve actually starts to open at a slightly
lower pressure. This is called the cracking pressure.
If the pressure downstream in the circuit increases to a point between
the cracking pressure and downstream pressure, some part of the pump
flow will be directed over the relief valve. For example, in figure 8, the
full open pressure of the relief valve is 1000 psi. However, the cracking
pressure is 980 psi.
Procedure Overview
In this procedure, you will demonstrate how the needle
valve and relief valve combine to control the flow rate in a
circuit. To do this, you will measure the pressure when the
relief valve first starts to open and then observe the flow as
pressure increases to the relief valve’s pressure setting.
NOTE
The hose with the open end fitting is shown in figure 10. The
open-end fitting being held over the opened filler/breather is
illustrated in figure 11.
NOTE
Verify that the flywheel is removed from the motor shaft. If it is
not, use a 3/32 inch allen wrench to remove it as you did in LAP
2 (Skill 4).
A B
SHUTOFF
VALVE NEEDLE
VALVE
3 MOTOR
1
2
OPEN END
RETURN
MANIFOLD RELIEF FITTING
VALVE A
FILLER
BREATHER
PORT
CAUTION
Before going to step 5, be sure the filler/breather cap has
been removed and the hose with the open-end fitting is directed
into the open reservoir.
Cracking Pressure________________________________(psi/kPa)
The cracking pressure should be approximately 330 psi / 2277 kPa.
❑ 9. Continue to slowly turn the needle valve’s knob CW. Observe the
flow through the relief valve and the speed of the motor.
You should observe that the motor slows down as the amount of
flow through the relief valve increases.
When the pressure stops increasing at gage A, you have reached
the relief valve’s pressure setting. This is where full flow is going
through the relief valve. The motor should then stop.
The check valve is a valve that allows fluid to flow in one direction
and completely blocks flow in the other direction. It is considered to be a
one-way directional control valve. Figure 12 shows a check valve used
with the Amatrol 850 system.
The check valve is one of the most commonly used hydraulic valves.
The circuit shown in figure 13 shows four common applications:
• Holding Prime - It is common for the oil to drain out of the inlet line
of a hydraulic pump when it has not been run for a long period. This
is called “losing the prime of the pump.”
Most larger pumps have difficulty regaining prime because the
atmospheric pressure is not enough to push the oil up the supply tube
to the pump’s inlet. A check valve is often installed in the inlet line
to hold the oil in the line.
• Avoid Pump Reversal - There are some types of hydraulic circuits
where the oil in the circuit will be forced through the pump
backwards if the electric motor is turned off. Many pumps can be
damaged if they are driven backwards. To avoid this problem, a
check valve is often installed at the outlet of the pump to keep the oil
pressure in the circuit from driving the pump in the reverse direction.
4. GENERATES
BACK- PRESSURE
1. HOLDS IN THE SYSTEM
PUMP
PRIME
• Bypass - Check valves are often used in circuits to bypass the flow
around certain components in one direction. This allows the
component to control the circuit’s operation in one direction and
have no effect in the other direction.
• Back Pressure - Many larger directional control valve designs use oil
pressure to shift the spool. With some designs there is a minimum
system pressure that must exist in order to shift the spool. A check
valve is often placed in the tank port to create a back pressure
sufficient to shift the spool.
Check valves are also used in other applications for holding actuators
locked in position and providing a free flow of oil to a hydraulic motor as
it decelerates to a stop. These applications will be explored in later LAPs.
FLAPPER
FLOW BLOCKED
SYMBOL EXPLANATION
FREE FLOW
INDICATES
DENOTES
BLOCKED
FREE FLOW
FLOW
LEFT TO
CHECK VALVE RIGHT
RIGHT
TO LEFT
OR
FREE FLOW
DENOTES
A SPRING
REQUIRED
Procedure Overview
In this procedure, you will demonstrate that a check
valve stops flow in one direction and lets it flow freely in the
other direction.
IN A B
OUT B A
IN
OUT
FREE
FLUID
FLOW
SPRING POPPET
FLUID
FLOW
BLOCKED
SPRING POPPET
Procedure Overview
In this procedure, you will design a circuit that will use
a check valve in a basic application.
IN A
OUT B
❑ 2. Connect your circuit design on the 850 trainer using the small bore
cylinder.
❑ 3. Perform the power unit checkout procedures.
❑ 4. Turn on the power unit and increase the relief valve’s pressure
setting to 300 psi/2070 kPa.
❑ 5. Open the shutoff valve.
❑ 6. Close the needle valve completely. Then open it 1/2 turn.
This will set the needle valve for a slow cylinder speed.
The flow control valve used in the 850 System combines a needle
valve and check valve together in one valve body to restrict flow in
one direction and allow free flow in the other direction. A typical flow
control valve is shown in figure 20.
The flow control valve is used with bidirectional actuators to make
the speed in one direction different from the other.
The flow control valve consists of a body with an inlet and outlet
port, an adjustment screw with a tapered end, an adjustment knob, a
check valve poppet and a spring, as shown in figure 21.
ADJUSTMENT
KNOB
NEEDLE
VALVE
VALVE
BODY
DIRECTION
DIRECTION
OF
OF
CONTROLLED
FREE FLOW
FLOW
SPRING POPPET
The two symbol techniques used for the flow control valve are
shown in figure 22.
SYMBOL EXPLANATION
INDICATES
INDICATES
ADJUSTABLE
ORIFICE
FLOW
CONTROLLED
FLOW FREE
FLOW
CHECK
VALVE
OR
INDICATES
IN SAME
ENVELOPE
(BODY)
Procedure Overview
In this procedure, you will connect a flow control valve
in a bidirectional actuator circuit to control the actuator
speed in one direction only.
DIRECTIONAL
CONTROL
SUPPLY VALVE
MANIFOLD
FLOW HOSE A
METER HOSE B
IN A
A B
SHUTOFF B
OUT
VALVE
FLOW
CONTROL
VALVE
RETURN MOTOR
MANIFOLD
❑ 2. If not already done, remove the flywheel from the shaft of the
motor.
❑ 3. Perform the power unit checkout procedures.
❑ 4. Turn on the power unit and adjust the power unit relief valve to
300 psi/2070 kPa.
❑ 5. Close the flow control valve completely by turning the adjustment
knob fully CW. Then open it 1/2 turn.
❑ 6. Open the shutoff valve.
ADJUSTMENT KNOB
CONTROLS FLUID FLOW
FLUID
FLOW IN OUT
FLUID
OUT IN FLOW
❑ 10. Try to slow down the motor by turning the flow control valve’s
adjustment CW.
You should observe that the flow control valve cannot control or
stop flow in the reverse direction, because its check valve allows
flow to bypass the flow control valve’s variable orifice.
❑ 11. Release the lever of the DCV.
Procedure Overview
In this procedure, you will demonstrate that the flow
rate through a standard (non-compensated) flow control
valve will change while the valve is controlling flow
whenever the actuator load changes.
NOTE
If the load spring is attached to the cylinder load block, you
must remove it before continuing. See LAP 3 (Skill 2) if you do
not remember how this is done.
SUPPLY DIRECTIONAL
MANIFOLD CONTROL
VALVE
LOCATE TEE'S AT THE
CYLINDER PORTS
IN A EXACTLY AS SHOWN
OUT B FLOW
SHUTOFF CONTROL
VALVE A VALVE
B
RETURN GAGE C
MANIFOLD
GAGE B TEE
LOAD
DEVICE
CYLINDER
WARNING
Keep your hands and fingers away from the load device when
you are operating the cylinder. Do not attempt to make
adjustments while the cylinder is moving.
❑ 7. Extend and retract the cylinder using the DCV to test its operation.
❑ 8. Adjust the flow control valve’s setting so that the cylinder takes
about two seconds to extend. Cycle the cylinder to test the speed
and use a stopwatch to measure the time. Then leave the cylinder
in the retracted position.
❑ 9. Now extend the cylinder again and observe the readings of gages
A, B, and C as the cylinder is extending. Record your readings in
the no load row.
No Load
Light Load
Heavy Load
❑ 10. Use the following steps to increase the load to a light load of 150
psi/1035 kPa.
A. Turn the load device’s cap screws CW, as shown in figure 27,
about 1/4 turn each.
B. Extend the cylinder again and observe the readings of gages B
and C. The load across the cylinder is indicated by the pressure
difference between gages B and C.
C. Continue to adjust the friction load device by turning the cap
screws until the pressure difference between gages B and C is
approximately 150 psi/1035 kPa while the cylinder is
extending. Cycle the cylinder several times, if needed, to make
this adjustment.
D. Leave the cylinder in the retracted position.
You have now set the light load on the cylinder.
Up to this point, you have studied the operation of the needle valve
and the flow control valve without concern to the placement in the
circuit. You have learned that you can place these valves at either the
inlet or the outlet of the actuator to control actuator speed. However, as
you will soon learn, this placement is important in some applications.
If you place the flow control valve at the inlet to the actuator, this is
called a meter-in flow control circuit, as shown in figure 28. In this
example, the circuit affects the speed of the cylinder while it extends.
The fluid leaving the other end of the cylinder is allowed to leave
unrestricted.
ROD
EXTENDING
DCV
SHIFTED
M
ROD
RETRACTING
DCV
SHIFTED
M
CRANE FORCES
ALWAYS ACT
IN THIS
DIRECTION
LIFT CYLINDER
Procedure Overview
In this procedure, you will connect a flow control valve
to meter in the flow and demonstrate the operation of this
circuit.
SUPPLY DIRECTIONAL
MANIFOLD CONTROL
VALVE
IN A
IN OUT
FLOW OUT B
GAGE
METER TEE
A
A
FLOW
CONTROL GAGE
VALVE C
B
RETURN TEE GAGE
MANIFOLD B
LARGE
BORE
CONNECT TEE'S CYLINDER
AT THE FLOW CONTROL VALVE
NOTE
You may have to extend and retract the cylinder several times
to get the slowest setting.
NOTE
You may have to extend and retract the cylinder several times
to obtain each of the readings.
NOTE
Read the pressure gages as accurately as possible.
METER-IN
0.5/1.9 / / /
0.75/2.9 / / /
1.0/3.8 / / /
1.25/4.8 / / /
NOTE
The instructions for installing the load spring are given in LAP
3 (Skill 4).
SUPPLY DIRECTIONAL
MANIFOLD CONTROL
VALVE
IN A
IN OUT
FLOW OUT B
GAGE
METER TEE
A
A
FLOW
CONTROL GAGE
VALVE C
B
RETURN TEE GAGE
MANIFOLD B
LARGE LOAD
BORE SPRING
CONNECT TEES CYLINDER
AT THE FLOW CONTROL VALVE
❑ 10. Close the flow control completely and then open it 1/4 turn.
❑ 11. Increase the relief valve setting until gage S reaches 300 psi / 2070
kPa.
You are now ready to observe the operation of a meter-in circuit to
control the speed of an aiding or overrunning load.
❑ 12. Retract and then extend the cylinder to observe its operation using
a meter-in flow control circuit.
You should observe that the cylinder rod jumps suddenly when the
DCV is shifted.
❑ 13. Repeat step 12 several times to observe the operation of a meter-in
circuit with an over-running load. Try several different flow
control settings to see if this has any effect.
You should observe that the meter-in circuit does not provide good
speed control to a cylinder with an over-running load.
❑ 14. Close the shutoff valve, reduce the relief valve to its minimum
setting and turn off the hydraulic power unit.
B831-XA LAP 4 HYDRAULIC SPEED CONTROL
Copyright © 2002 Amatrol, Inc. 44
❑ 15. Move the handle of the DCV back and forth to remove any
pressure still in the circuit.
Leave the load spring installed on the cylinder. It will be used in
the next skill.
ROD
EXTENDING
DCV
SHIFTED
M
DCV
SHIFTED
Procedure Overview
In this procedure, you will connect a flow control valve
in a meter-out flow control circuit and demonstrate the
operation of this circuit when the load is aiding.
❑ 1. If not already installed, mount the load spring behind the rod cam
and set up the meter-out flow control circuit shown in figure 35.
In this circuit, the flow control valve will control the flow rate only
when the cylinder extends. Pressure gages A and B indicate the
pressure drop across the valve. The flowmeter indicates the flow
rate to the cylinder. The load spring provides an aiding load during
extension.
RETURN
MANIFOLD
LARGE LOAD
BORE SPRING
CONNECT TEES CYLINDER
AT THE FLOW CONTROL VALVE
NOTE
You should observe that very slow and smooth cylinder
extension is easily obtained. This would not be the case if using
pneumatics.
70 to 90 seconds is typical.
❑ 11. Perform the following substeps to experiment with your ability to
set specific cylinder speeds with a meter-out circuit.
A. Adjust the flow control valve so that the flowmeter reads 0.5
gpm / 1.9 lpm while the cylinder is extending. To do this, you
will have to make several trial adjustments to the flow control
valve’s setting. Cycle the cylinder after each adjustment to
observe the extend time.
B. Once the flow is adjusted, extend the cylinder again and record
the time required to extend in the table. Also, record the
readings of pressure gages A, B, and S while the cylinder is
extending.
You should observe that gages A and S read near 400 psi/2760
kPa because the rest of pump flow is going over the relief valve
gage. Gage B should be minimum because during extend it is
indicating return pressure.
NOTE
You may have to extend and retract the cylinder several times
to obtain the readings.
NOTE
Record the pressure gage readings as accurately as possible.
0.5/1.9 / / /
0.75/2.9 / / /
1.0/3.8 / / /
1.25/4.8 / / /
Procedure Overview
In this procedure, you will design a circuit that will
separately control the speed of an actuator in each
direction.
❑ 1. Complete the circuit shown in figure 37 so that you can control the
speed of the cylinder in each direction using a separate flow
control valve. Draw the two flow control valves so that each valve
provides meter-out flow control.
Label your flow control valves FC1 and FC2. FC1 should control
the extend speed and FC2 should control the retract speed.
SUPPLY DIRECTIONAL
MANIFOLD CONTROL
VALVE
IN A
OUT B
LARGE
RETURN BORE
MANIFOLD CYLINDER
FC 1 controls _____________________________(Retract/Extend)
You should observe that only the extend speed is affected.
❑ 7. Reset FC 1 to 1/2 turn open.
❑ 8. Now adjust FC 2 to several different settings to test its effect on
the circuit. Extend and retract the cylinder after each new
adjustment and observe the cylinder’s speed.
You should observe that the speed of the cylinder changes for only
one direction of motion when FC 2 is readjusted. This should be
the direction opposite that of FC 1. Record below this direction.
FC 2 controls _____________________________(Retract/Extend)
❑ 9. Reduce the relief valve pressure to minimum, close the shutoff
valve and turn off the power unit.
❑ 10. Move the handle of the DCV back and forth to remove any
pressure in the circuit.
❑ 11. Now design and connect a new circuit that performs the same task
as your circuit in figure 37 except that it uses meter-in speed
control.
FC 1 controls _____________________________(Retract/Extend)
You should observe that only the extend speed is affected.
❑ 15. Reset FC 1 to 1/2 turn open.
❑ 16. Now adjust FC 2 to several different settings to test its effect on
the circuit. Extend and retract the cylinder after each new
adjustment and observe the cylinder’s speed.
You should observe that the speed of the cylinder changes for only
one direction of motion when FC 2 is readjusted. This should be
the direction opposite that of FC 1. Record below this direction.
FC 2 controls _____________________________(Retract/Extend)
❑ 17. Reduce the relief valve pressure to minimum, close the shutoff
valve and turn off the power unit.
❑ 18. Move the handle of the DCV back and forth to remove any
pressure in the circuit.
Procedure Overview
In this procedure, you will design a circuit to provide
two speeds to an actuator as it operates in one direction.
SUPPLY
MANIFOLD DCV
MOTOR
IN A
OUT B
RETURN
MANIFOLD
FLOW
METER
OUT IN
Flow Rate
Rod Speed =
Area
English Units:
Flow Rate (gpm ) × 231
Extend Rod Speed (in/min) =
Piston Area (in 2 )
S.I. Units:
Flow Rate (lpm ) ×1000
Extend Rod Speed (cm/min) =
Piston Area (cm 2 )
EXTEND
SPEED (RS)
RS = ROD SPEED
Procedure Overview
In this procedure, you will calculate the extend speeds
of the cylinders used in the 850 series trainer for several
flow rates as well as determine what cylinder size is
needed to produce extend speeds when given the flow
available.
EXTEND SPEED
0.5/1.9 / /
0.75/2.9 / /
1.0/3.8 / /
1.25/4.8 / /
Flow Rate
Rod Speed =
Area
English Units:
Flow Rate (gpm ) × 231
Retract Rod Speed (in/min) =
Annular Area (in 2 )
S.I. Units:
Flow Rate (lpm ) ×1000
Retract Rod Speed (cm/min) =
Annular Area (cm 2 )
Procedure Overview
In this procedure, you will calculate the retract speeds
of the cylinders on the hydraulic actuator module and
perform other calculations based on retract speeds.
RETRACT SPEED
0.5/1.9 / /
0.75/2.9 / /
1.0/3.8 / /
1.25/4.8 / /
NOTE
Be sure you adjust your calculation to account for the area of
the rod. The diameter you will need to specify is the piston
diameter for the cylinder.
Flowrate needed________________________________(gpm/lpm)
Your calculations should produce a flowrate of 3.44 gpm / 12.57
lpm.
Area × Stroke
Cylinder Stroke Time =
Flow Rate
English Units:
Area (in 2 ) × 60 × Stroke (in )
Stroke Time (sec) =
Flow Rate (gpm ) × 231
S.I. Units:
Area (cm 2 ) × 60 × Stroke (cm )
Stroke Time (sec) =
Flow Rate (lpm ) ×1000
NOTE
Where area is either the piston area for extend or the annular
area for retract.
Procedure Overview
In this procedure, you will be using the 850 series
cylinders again. You will then compare these calculations
with the actual measurements made in Skill 4.
0.5/1.9
0.75/2.9
1.0/3.8
1.25/4.8
0.5/1.9
0.75/2.9
1.0/3.8
1.25/4.8
_____________________________________________________
You should observe that at the same flow rates, retract stroke times
are shorter than extend stroke times.
❑ 4. Now compare the large bore cylinder calculated stroke times
during extend with those obtained in skill 4. Are they reasonably
close?
______________________________________________(Yes/No)
You may find the stroke times obtained in Skill 4 quite different
than the calculated values because of timing and flow meter
inaccuracies. Generally they should agree.