Flow Control Circuits

To control the speed of an actuator, most designers use flow controls. Air circuits normally need controlled flow because the plant air compressor is greatly oversized for almost any given circuit. Hydraulic circuits usually have a dedicated power source sized to meet the cycle time so flow restrictors are unnecessary. Flow controls always generate some heat in hydraulic circuits, so consider some other method of controlling actuator speed where possible. The circuit examples in this chapter explain the types of flow-control systems and how to apply them. Figures 10-1 and 10-2 show symbols for fixed orifices, rudimentary components that will control flow. A fixed orifice can be a simple restriction in a line or a factory-preset control with pressure compensation and a bypass. Their low cost and the fact that they are tamper-proof are two main reasons for using fixed orifices.

Fig. 10-1: Fixed orifice.

Fig. 10-2: Pressure- and temperature-compensated fixed orifice.

Use the needle valve shown in Figure 10-3 when control of fluid flow in both directions is necessary. Add the check valve arrangement shown in Figure 10-4 when a needle valve needs pressure compensation in both directions. These check valves, sometime referred to as bridge rectifiers, force fluid to flow through the needle valve in the same direction regardless of actuator movement. (Remember, pressure compensation only works in one direction of flow.)

Fig. 10-3: Needle valve.

Fig. 10-4: Pressure- and temperature compensated needle valve.

When talking about flow-control hardware, some manufacturers use different terminology. Normally the term flow control refers to an adjustable needle valve with an integral bypass, as pictured in Figure 10-5. This type of flow control meters flow in one direction and allows free flow in the opposite direction. However, some companies identify the flow control in Figure 10-5 as a throttle valve. These companies say a flow control must have a bypass and be pressure-compensated as shown in Figure 10-6.

Fig. 10-5: Flow control with bypass (or throttle valve).

When a hydraulic actuator needs accurate speed control, use a pressure-compensated flow control. System pressure fluctuations or load changes will cause actuator velocity to change. Regardless of the cause of the pressure differences, flow across the orifice will change unless the flow control is pressure compensated. Only use a pressurecompensated valve when very accurate speed control is needed because its cost is as much as six times that of a noncompensated valve.

Fig. 10-6: Pressure- and temperature-compensated flow control.

There are three types of flow control circuits from which to choose. They are: meter-in, meter-out, and bleed-off (or bypass). Air and hydraulic systems use meter-in and meter-out circuits, while only hydraulic circuits use bleed-off types. Each control has certain advantages in particular situations. Figure 10-7 shows a meter-in flow-control circuit for a cylinder. Notice that a bypass check valve forces fluid through an adjustable orifice just before it enters the actuator. Figure 10-8 shows the circuit while the cylinder is extending with the pressures and flows indicated. With a meter-in circuit, fluid enters the actuator at a controlled rate. If the actuator has a resistive load, movement will be smooth and steady. This is because hydraulic fluid is almost incompressible.

Fig. 10-7: Meter-in flowcontrol circuit at rest.

In pneumatic systems, cylinder movement may be jerky because air is compressible. As air flows into a cylinder, as depicted in Figure 10-9, pressure increases slowly until it generates the breakaway force needed to start the load moving. Because the subsequent force needed to keep the load moving is always less than the breakaway force, the air in the cylinder actually expands. The expanding air increases the cylinder speed, causing it to lunge forward. The piston moves faster than the incoming air can fill the cylinder, pressure drops to less than it takes to keep the cylinder moving and it stops. Then pressure starts to build again to overcome breakaway force and the process repeats. This lunging movement can continue to the end of the stroke. A meter-out circuit is the best control to avoid air-cylinder lunging.

Fig. 10-8: Meter-in flowcontrol circuit with cylinder

extending.

Figure 10-7 shows the components in a meter-in flow-control circuit. Notice that a bypass check valve forces fluid through an adjustable orifice just before it enters the actuator. Figure 10-8 shows an extending hydraulic cylinder and indicates the pressures and flows in various parts of the circuit. With a meter-in circuit, fluid enters the actuator at a controlled rate. If the actuator has a resistive load, movement will be smooth and steady with a hydraulic circuit. This is because oil is almost non-compressible.

Fig. 10-9: Pneumatic meter-in flow-control circuit with cylinder extending

In the case of an air system, pressure builds slowly and cylinder movement may be jerky. This jerky movement comes from compressibility of the air. As air enters the cylinder, Figure 10-9, pressure builds slowly until it generates the breakaway force to start the piston moving. Because moving force is always less than breakaway force, air in the cylinder expands. The expanding air speeds up cylinder movement, causing it to lunge forward. This increased speed moves the piston faster than the incoming air can fill the space behind it, so pressure drops to less than it takes to keep it moving and the cylinder stops. After the cylinder stops, pressure starts to build again to develop breakaway force and the process repeats. This lunging movement can continue to the end of the stroke. A meter-out circuit is the best control for an air cylinder.

Fig. 10-10: Meter-in flowcontrol circuit for overrunning load with cylinder extending.

If the actuator has an overrunning load, such as in Figure 10-10, a meter-in flow control will not work. When the directional valve shifts, the vertical load on the cylinder rod makes it extend. Because fluid cannot enter the cylinders cap end fast enough, a vacuum void forms there. The cylinder then free falls, regardless of the setting of the meter-in flow adjustment. The pump will continue to supply metered fluid to the cap end of the cylinder and will eventually fill the vacuum void. After the vacuum void fills, the cylinder can produce full force.

3-speed meter-in circuit

The schematic diagram in Figure 10-11 shows a 3-speed, meter-in flow-control circuit using modular valves. Energizing different combinations of solenoids changes cylinder speed at will. To get additional speeds, add more tandem-center directional valves and flow-control modules like station DV01. The limiting factor would be pressure drop through the valves tandem centers. Using a bar manifold and modular valves eliminates many fittings and possible leak sources. As in all meter-in circuits, the pressure-compensated pump shown here generates less heat than a fixed-volume pump.

Fig. 10-11: Three -speed meter-in flow-control circuit using modular valves mounted on bar manifold at rest with pump running.

To extend the cylinder at fast speed, shift the valves as shown in Figure 10-12. Energizing solenoid A2on directional valve DV02 sends fluid through the meter-in flow-control module directly under it to the cylinders cap end. This condition is always set for the fastest extension speed. Solenoid A2 stays energized for all extension speeds.

Fig. 10-12: Three -speed meter-in flow-control circuit using modular valves mounted on bar manifold extending at fast speed.

Energizing solenoid B1 on directional valve DV01, Figure 10-13, sends pump flow through the right-hand flow control in the module underneath it. This will produce a slower speed -- here called middle speed. Either solenoid A1 or B1 could produce middle speed, making the opposite solenoid produce slow speed. As with fast speed, the cylinder speed is variable, but never faster than fast speed.

Fig. 10-13: Three -speed meter-in flow-control circuit using modular valves mounted on bar manifold extending at middle speed.

By actuating solenoid A1 on directional valve DV01, fluid passes through the left-hand flow control in the module underneath it. This will produce a different speed here called slow speed. The cylinder can retract rapidly or at any of the same slower-flow settings as above. By energizing solenoid B2of directional valve DV02, flow will pass through the opposite meter-in flow control. This means fast-speed retracting can be different from the extending speed. The middle and slow speeds will be at the same flow rate as extension. Cylinder speed during these reduced flows will be somewhat faster due to the decreased rod-end area. A simple manifold can give multiple speeds inexpensively, while eliminating potential plumbing leaks. Note: Select a valve for DV01 that can withstand tank-line backpressure.

Speed changes with this meter-in circuit will be smooth because the cylinder can coast while slowing down. (It also is possible that the cylinder could cavitate when slowing down, so an anti-cavitation check valve may be needed.)

Fig. 10-14: Three -speed meter-in flow-control circuit using modular valves mounted on bar manifold extending at slow speed.

Meter-in flow control of a running-away load

Figures 10-15 and 10-17 show a running-away load controlled by a meter-in circuit and counterbalance valves. The meter-in flow control works exactly as explained previously, while a counterbalance valve makes cylinder movement resistive. (See Chapter 5 for an explanation of counterbalance valves.) Figure 10-16 pictures a bleed-off flow control circuit that gives the same results as a meter-in circuit -- without most of the heat generation.

Fig. 10-15: Meter-in flowcontrol circuit for vertical cylinder extending with overrunning load. Counterbalance valve prevents load from

falling.

A meter-in flow control circuit for an over-running load is not the normal design but it may be necessary when the circuit has a pressure switch or a sequence valve. In any meter-in circuit with a fixed-volume pump, the wasted energy will heat the fluid. In the circuit in Figure 10-15, almost 95% of the power used by the system becomes heat. In this circuit, fluid from the pump enters the cylinder as fast as the meter-in flow control allows. A counterbalance valve at the rod-end port keeps the cylinder from running away as it extends.

Fig. 10-16: Bleed-off or bypass flow-control circuit for vertical cylinder extending with overrunning load. Counterbalance valve prevents load from falling.
.

To save energy while using a fixed-volume pump, the circuit in Figure 10-16 works well. A bleed-off or bypass flow control greatly reduces the amount of wasted energy. With a bleed-off circuit, excess pump flow goes to tank at the pressure required to move the cylinder. In the circuit in Figure 10-16, pressure would be approximately 50 psi as the cylinder extends. The extension-stroke speed is still infinitely variable, while pressure in the cylinder cap end line never goes higher than that caused by load resistance.

Fig. 10-17: Meter-in flowcontrol circuit with loadsensing pressure-compensated pump and vertical cylinder extending with over-running load. Counterbalance valve prevents load from falling.

Figure 10-17 shows another way to reduce energy loss and heat generation using as load-sensing, pressurecompensated pump in conjunction with a meter-in flow-control circuit. A sensing line, teed into the cylinder cap-end line after the meter-in flow control, transmits pressure information to the pump. With a load-sensing, pressure-compensated pump, pressure at the pump outlet stays 150 to 200 psi higher than the load until it tries to go above the compensators pressure setting. The only energy loss here is the 150- to 200-psi pressure drop across the flow control at the volume set. (Heat generation within a load-sensing pump circuit is explained later in this Chapter.)

When meter-in circuits are necessary

In some cases a meter-in circuit is the only way to control the speed of an actuator -- even for pneumatic devices. Figures 10-18 through 10-21 show several instances requiring meter-in circuits.

Fig. 10-18: Meter-in flowcontrol circuit with pressure switch for end-of-stroke indication.

Many machine circuits use pressure switches to indicate when an actuator meets resistance. If pressure in the actuator builds prematurely, the machine cycle gets out of phase. With the meter-in circuit shown in Figure 10-18, pressure in the cylinder will be just enough to move the cylinder and its attachments until it reaches the load. With a meter-out circuit, pressure in the cylinder cap end would build as soon as the directional valve shifts, tripping the pressure switch long before the cylinder contacts the load.

Fig. 10-19: Meter-out flowcontrol circuit with pressure switch for end-of-stroke indication.

However, it is possible to use a pressure switch with a meter-out flow control circuit. In Figure 10-19, notice that the pressure switch is on the cap-end line to the cylinder. It passes a signal when the cylinder cannot extend farther. Notice also that the pressure switch setting is very low (50 psi). While the cylinder is moving, oil flowing from the cylinder head-

end port remains pressurized by the meter-out flow control. When the cylinder contacts the load, pressure in the headend port drops, actuating the pressure switch and sending a signal. (Use a normally open, 3-way, pilot operated, springreturn directional valve in place of the pressure switch to produce an air or hydraulic pilot signal.) The pressure-decaying circuit in Figure 10-19 works well in pneumatic circuits because metering air flow out provides good control. Several companies furnish air logic elements designed specifically for this type of circuit.

Fig. 10-20. Meter-in flowcontrol circuit with sequence valve for end-of-stroke indication.

Sequence valves often are used to start a second actuator after a cylinder meets resistance and builds tonnage. With the meter-in flow control shown in Figure 10-20, pressure in the cylinder cap end increases when -- but not before -- the cylinder contacts the work. Pressure at the sequence valves inlet stays lower than its spring setting while the actuator is moving. (With a meter-out circuit, pressure in the cylinders cap end would go to system pressure when the directional valve shifts. Because of this, flow to the secondary circuit would take place prematurely. The vertical single-acting, weight-return cylinder shown in Figure 10-21 needs meter-in control as it extends. This will be the case even if it is a pneumatic cylinder where meter-out control works best. For a different retraction speed, use a second meter-out flow control (as shown in Figure 10-21).

Fig. 10-21. Meter-in flowcontrol circuit for a single-

acting cylinder extending.

Note: A pressure switch or a sequence valve will only indicate that pressure has reached a certain level. What caused the pressure build-up is unimportant. If the actuator positively has to be at a certain position before the next function starts, do not use a pressure-sensing device. Always use a limit switch. (Use a pressure switch or sequence valve in series with the limit switch if cylinder position and force are both important.)

Action of a meter-in air circuit with a varying load

When using a meter-in circuit on an air cylinder with a variable load, movement will not be consistent. Depending on the required range of forces, movement may be smooth, the cylinder may over-speed, or it may even stop. In Figure 10-22, the cylinder is moving smoothly at a pressure difference of 30 psi. (It takes 30 psi in the bore size being used to generate the force to move the load.) If the load remains constant, the cylinder can -- and probably will -- advance smoothly.

Fig. 10-22. Meter-in pneumatic flow-control circuit for loaded cylinder extending slowly and smoothly toward a second load.

Fig. 10-23. Meter-in pneumatic flow-control circuit as cylinder contacts second equal load. Cylinder stops while cap-end pressure builds to produce

force required.

When the load doubles, as in Figure 10-23, 30 psi is not enough to keep the cylinder moving. At this point the cylinder will stop until pressure in the cap end reaches 60 psi. (The meter-in flow setting determines how long this takes.)

Fig. 10-24. Meter-in pneumatic flow-control circuit moving both loads after cap-end pressure reaches load requirement.

Once pressure in the cylinder cap end reaches 60 psi, Figure 10-24, the cylinder starts moving again. If the higher load stays constant, movement is steady. When the second load is reduced, as diagrammed in Figure 10-25, 60 psi in the cap end is more pressure than needed. This high pressure will cause the cylinder to lunge forward and, as a result, pressure in the cap end will start to decay. The amount of lunge is in direct proportion to the total volume of air in the cylinders cap end and the piping leading to it. Next, as Figure 10-26 shows, once decompression reaches 30 psi, the cylinder slows to its original speed.

Fig. 10-25. Meter-in pneumatic flow-control circuit as second equal load drops off. Cylinder lunges forward as pressure in cap end decreases.

If this stop/lunge/over-speed problem is intolerable and air is the required power source, add some method of oil control to the circuit. (See Chapter 3 on air-oil circuits.)

vvv