K J SOMAIYA COLLEGE OF ENGINEERING, MUMBAI-77

(CONSTITUENT COLLEGE OF SOMAIYA VIDYAVIHAR UNIVERSITY)

Presented by:
Prof. R. B. Pansare

2.2 DCV

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 Pneumatic system
• Pneumatic technology deals with the study of behaviour and applications of
compressed air in our daily life in general and manufacturing automation in particular.
• Pneumatic systems use air as the medium which is abundantly available and can be
exhausted into the atmosphere after completion of the assigned task.
• Pneumatic systems are systems that use
gas or pressurized air to move cylinders,
motors or other mechanical parts.
• Pneumatics applications are relevant to a
wide variety of industries, including
construction, healthcare, mining, the
automotive industry and many others.

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 Basic Components of Pneumatic System
• Air filters: These are used to filter out the
contaminants from the air.
• Compressor: Compressed air is generated by using
air compressors. Air compressors are either diesel or
electrically operated. Based on the requirement of
compressed air, suitable capacity compressors may be
used.
• Air cooler: During compression operation, air
temperature increases. Therefore coolers are used to
reduce the temperature of the compressed air.
• Dryer: The water vapour or moisture in the air is
separated from the air by using a dryer.
• Control Valves: Control valves are used to regulate,
control and monitor for control of direction flow,
pressure etc.
• Air Actuator: Air cylinders and motors are used to
obtain the required movements of mechanical
elements of pneumatic system.
• Electric Motor: Transforms electrical energy into
mechanical energy. It is used to drive the compressor.
• Receiver tank: The compressed air coming from the
compressor is stored in the air receiver.

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 1. Compressor
• It is a mechanical device which converts mechanical energy into fluid energy.
• The compressor increases the air pressure by reducing its volume which also increases the temperature
of the compressed air. The compressor is selected based on the pressure it needs to operate and the
delivery volume.
• The compressor can be classified into two main types
a. Positive displacement compressors and
b. Dynamic displacement compressor

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 2. Receiver
• Since the pneumatic system needs
continuous supply of air, this
compressed air has to be stored.
• The air receiver smoothens the
pulsating flow from the compressor.
• It also helps the air to cool and
condense the moisture present.
• The pressure in the receiver is held
higher than the system operating
pressure to compensate pressure loss
in the pipes.

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 3. Filters(F), Pressure regulation(R), Lubricators(L)-FRL

Air filter and water trap: used to Regulators: the pressure in the receiver is Lubricator: Air is passed
• prevent any solid contaminants always kept higher than the system through a lubricator in order to
from entering in the system. pressure. form a mist of oil and air to
• condense and remove water At the application site, the pressure is provide lubrication to the
vapour that is present in the regulated to keep it constant. mating components.
compressed air.

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 3. Filters(F), Pressure regulation(R), Lubricators(L)-FRL

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 4. Control Valves/Direction control valves (DCV)
• Directional control valves are used in pneumatic systems to direct or
stop the flow of compressed air or oil to their appliances.
• Most used elements in pneumatic systems.
• Can be used to actuate a cylinder, a larger industrial valve, or air
tools.
• Can have two or more ports and fulfil various circuit functions.
• The function and behaviour of the valve can be indicated by a
symbol.
• The symbol however doesn't explain the construction of the valve.
• Can be actuated by different means, such as manual actuation or
solenoid actuation.
• Directional control valves (DCVs) are one of the most fundamental
parts of hydraulic and pneumatic systems.
• DCVs allow fluid flow (hydraulic oil, water or air) into different
paths from one or more sources.
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 Classification of DCV
 Directional control valves can Typically the ports or labelled with a single letter:
be classified according to:
o P:pressure, or supply of high-pressure working
• number of ports fluid to be supplied to actuator by the valve.
• number of positions o T: tank, drain, or return. Working fluid from
• actuating methods actuator returned to be re-pressurised from the
• type of spool valve.
o A: actuator Working fluid through the valve for
 Types
the action of the actuator.
• Check valves o B: actuator, opposing Working fluid through the
• Shuttle Valves valve to opposing action of actuator.
• Two-way valves o X: external operation Working fluid to operate
• Three-way valves the valve.
o Y: external operation, opposing Working fluid to
• Four-way valves operate the valve in opposition, or to return to
pilot valve.
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 Check Valves: Shuttle valve: Spool type valve:
• Spool-type valves are
A shuttle valve allows the flow in two
commonly used as they can be
different directions.
transferred to two, three or
more routing fluid locations
between various inlet and
outlet ports combinations.
o Fluid flows through the inlet, a • These are commonly used for
small pressure is needed to open steering control of actuators
the valve seat in this direction. o Two positions of the shuttle valve are because a single valve can
o The valve opens when there is a shown here. produce extension, retraction
flow through the inlet. o When the pressure of the flow on one and neutrality:
o Whenever there is a flow side increases the valve closes the • There are three variants of
opposite to this direction the other path. spool type valve Two-way,
valve shuts. o The closing/opening condition for three-way and Four-way
o The pressure in the opposite both paths are illustrated in the above valves:
direction press the ball against figure.
the valve seat, thus close the path. o Shuttle valves are used where there
are two pumps which are used in a
way if one fails to maintain the outlet
pressure the other pump supply the
flow as a backup.
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 Two-way Valves: Three-way valves:
Two-way valves are also simple two • These valves have three nodes that’s why named three-way
positions ON/OFF valves but actuated by valve and three-way valves allows two positions of actuation
actuators such as solenoid actuators, in ON condition.
hydraulic actuators etc.

 A three-way valve has two plug actuators each plug controls the flow in two
different ways. The two plug positions are shown in the above figure. When
• There is normally closed and normally opened two-way
one of the plugs closes a node other one opens the other node.
valves, external actuation is needed to do the position  This normally closed valve neutralize the position of the actuator closing both
change of the valve actuator. the node to close the valve.
• A flow path is established or closed when the actuator is  Three-way directional valves are available for manual, mechanical, pilot,
moved. These valves are also called as on-off valves solenoid actuation.

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 Four-way Valve:
• Four-way valve or three position valves which got three working positions for the actuators to control the flow
direction.

• These valves are generally used to operate cylinders

and fluid motors in both directions hydraulically.
• These valves are available with a choice of actuation,
manual, mechanical, solenoid, pilot & pneumatic.
• Four-way valve comes with two or three positions.
• One should note that the graphical symbol of the
valve shows only one tank port even though the
physical design may have two as it is only concerned
with the function.
• Three- position, four-way DCV have different
varieties of centre configurations.
• The common varieties are the open centre, closed
centre, tandem centre, floating centre, & regenerative
centre with open, closed and tandem are the three
basic types
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 Poppet-type directional control valves
• Fluid at the inlet port passes through the control
orifice to the backside of the poppet.
• The tip of the spring-loaded armature closes off
the outflow orifice to trap fluid behind the poppet.
• As the symbol shows, the valve is a check valve
that stops flow from inlet to outlet in the normal
condition.
• This design will not stop flow from outlet to inlet,
although flow in this direction may be at a reduced
rate.
• If using this valve for reverse free-flow in its
normally closed condition, make sure to choose
one with free-flow capability.

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 Rotary Directional Control Valve
• 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.

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 Pneumatic Valves
• 2 by 2 way NC

 3 by 2 way NC
 3 by 2 way NO

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 • 3 by 2 way NO 2

2 12 10

12 10

3 1

3 1

• 5 by 2 way valve

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 Valve Actuation

PLUNGER ROLLER
TRIP

PUSH
BUTTON SOLENOID

LEVER DIAPHRAGM

FOOT
ROLLER PEDAL

PILOT AIR SPRING

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• Throttle Valve

 No Return Valve

 Flow Control Valve

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 Pneumatic Valves
• AND Gate
Output

Input 1 Input 2

 OR Gate (Shuttle Valve)

Output

Input 1 Input 2

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Normally Closed and Normally Open:
o The term indicates the position a valve takes when it is not
energized.
o A NC valve does not allow any air to pass through it when it
is not energized: the port is 'closed'.
o A NO valve, on the other hand, does allow air to pass
through, exhausting the working port when it is not operated.

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 Advantages of Pneumatics
o Clean:
−Pneumatic systems are clean because they use compressed air. If a pneumatic system develops a leak, it will
be air that escapes and not oil. This air will not drip or cause a mess which makes pneumatics suitable for
food production lines.
o Safe:
−Pneumatic systems are very safe compared to other systems. We cannot, for example, use electronics for
paint spraying because many electronic components produce sparks and this could cause the paint to catch
fire.
o Reliable:
−Pneumatic systems are very reliable and can keep working for a long time. Many companies invest in
pneumatics because they know they will not have a lot of breakdowns and that the equipment will last for a
long time
o Economical:
−If we compare pneumatic systems to other systems, we find that they are cheaper to run. This is because the
components last for a long time and because we are using compressed air.
o Flexible:
−Once you have bought the basic components, you can set them up to carry out different tasks. Pneumatic
systems are easy to install and they do not need to be insulated or protected like electronic systems.

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 Push button switches

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Limit switches Solenoids

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 Switches

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 Relays

https://youtu.be/PhUqGrOEcCE

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 Pressure control valves: direct operated and pilot
operated types.
• Pressure control valves regulate or release the pressure of the hydraulic
oil in a system.
• Pressure-control valves are found in practically every pneumatic and
hydraulic system.
• There are poppet type, spool type, direct-acting, pilot-operated, and
bidirectional cartridge valves.
• Pressure reducing valves are available for flow rates ranging from 0 to
189 lpm (0 to 50 gpm) and operating pressures from 69 to 427 bar (1000
to 6200 psi).

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• They help in a variety of functions, from keeping system pressures below a
desired limit to maintaining a set pressure level in part of a circuit.
• Different types of pressure control valves include relief, reducing, sequence,
counterbalance, safety, and unloading.
• All of them are typically closed valves, except for reducing valves, which are
usually open.
• For most of these valves, a restriction is necessary to produce the required pressure
control.
• One exception is the externally piloted unloading valve, which depends on an
external signal for its actuation, which normally comes from a digital pressure
regulator.
• In certain applications, like ventilators and anesthesia machines, the flow must
be consistent at all times.
• Variations in the flow of gases can lead to serious injury or death.
• That’s why control valves are so important.
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 Commonly used valves:
• Pressure Relief Valves
• Sequencing Valves
• Pressure-Reducing Valves
• Counterbalance Valves
Relief Valve Parts :
1. Inlet Nozzle,
2. Valve Seat,
3. Seat Holder,
4. Valve Body,
5. Set Pressure Adjusting
Screw,
6. Cap,
7. Spring,
8. Bonnet,
9. Seal
Figure symbol of Pressure relief valve
Pressure Relief Valves
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 o A sequence valve is widely used in a hydraulic system these
valves are pressure control valves.
o The sequence valves are similar to a pressure relief valve
and these valves are used where a set of operations are to be
controlled in a pressure-related sequence.
o The major function of a sequence valve is to divert the flow
in a predetermined sequence.
o This valve is a pressure-actuated valve and its construction
is very much similar to a relief valve and normally a closed
valve.
Sequencing Valves o The operating principle of the sequence valve is that when
the main system pressure overcomes the spring setting then
the valve spool will be moved.
o So the outlet of the sequence valve would remain closed till
the upstream pressure builds up to a predetermined value so
then the valve would open to allow the transfer of air from
the inlet to the outlet.

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 Sequence Valve
• The sequence valves are mostly used to force two actuators to operate in sequence.
• The sequence valve has a good feature and it is that this valve has a separate drain connection
from the spring chamber and it is because a high pressure could occur in the output port
during the normal operation conditions.
• When the pressure rises beyond its limit the pressure sequence valve would allow the flow to
occur in another part of the system.
• The pressure sequence valves are installed in pneumatic controls in which a specific pressure
is needed for its switching operation.

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 Pressure-Reducing Valves
• A pressure-reducing valve is a self-operating valve that is used to
reduce any excess pressure in a system.
• Sometimes this valve is also known as pressure reducing regulator.
• The basic function of pressure-reducing valves is to reduce higher
pressure into lower.
• They are commonly used in water, steam, and oil & gas industries.
• A Pressure Reducing Valve can be defined as a self-acting
automatic control valve for reducing a higher unregulated inlet
pressure to a constant, reduced outlet pressure regardless of the
fluctuations in the upstream water pressure.
• In this article, we will learn about the functions, types, applications,
and advantages of pressure-reducing valves.

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 Functions of Pressure Reducing Valves
A pressure-reducing valve is able to control pressure through the fully automatic self-
contained operation without the necessity of an external power source.
The main functions of a pressure-reducing valve are:
• In steam systems, pressure-reducing valves are used to get precise control of
downstream pressure. These valves automatically adjust the valve opening and adjust
the pressure to keep it constant during pressure fluctuations.
• Properly selected pressure-reducing valves can be used for water hammer protection
under defined conditions.
• They can also be used as bypass valves for saving the system during power failures.
• Pressure-reducing valves are capable of taking rapid action by immediate sensing and
adjusting based on the downstream pressure.
•

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 Counterbalance Valves
• A counterbalance valve is a hydraulic
device that maintains back pressure in a
hydraulic system, particularly when
dealing with suspended or overriding
loads.
• Its primary function is to prevent the load
from falling uncontrollably by allowing
controlled descent only when the hydraulic
system is actively supplying pressure.

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 DIRECT ACTING VALVE :
• In Direct acting valve, typically a spring diaphragm actuator is used to
control the valve opening.
• On one side of the Diaphragm, controlled pressure is acting and on
another spring force is applied.
• Spring exerts valve opening force and downstream pressure acting on
another side of diaphragm exerts valve closing force.
• When controlled downstream pressure reduces below set pressure, valve
opens due to unbalanced spring force.
• Whereas in case of upstream pressure control valve, spring exerts valve
closing force to keep the valve in closed position and controlled upstream
pressure exerts valve opening force on other side of diaphragm, which
opens the valve when upstream pressure rises above set pressure.
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 Pilot Operated Valves
• Pilot valves, are control valves that use a small pilot valve to control the
larger main valve.
• The pilot valve is typically operated by a pressure signal or an electric
signal, which in turn controls the flow of fluid through the main control
valve.

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 Flow control valves: temperature compensated,
pressure compensated, pressure and temperature
compensated, and non-compensated flow control valves.
What is a flow control valve?
• Used to regulate the flow rate of compressed air
• By controlling the flow rate, the speed of the pneumatic cylinder can also
be regulated directly.
• Good throttling valve contributes to reducing wear due to a lower kinetic
load.
• Also support a more steady and thus reliable movement.
• If the speed is unthrottled, the velocity can fluctuate.
• This in turn can lead to a stick/slip effect and thus to a faltering motion.
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 Temperature compensated FCV
• Valve that can maintain a set flow
rate even when the temperature of the
fluid or the load pressure changes.
• This is possible because temperature
compensators adjust the control
orifice openings to compensate for
the effects of temperature
fluctuations on the viscosity of the
fluid.

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 Pressure-compensated flow control valve
• A heavy load on the cylinder will increase the pressure at the outlet of the
valve ahead of the cylinder compared to a lighter load.
• The change in pressure drop across the valve alters the flow rate it
delivers to the cylinder.
• Pressure-compensated flow control valves automatically adjust to such
changes in pressure drop to deliver a constant flow rate that will provide
smooth, constant-speed motion of the hydraulic cylinder.

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 Pressure and temperature compensated FCV
• Its operation is essentially same as the restrictor type, pressure
compensated flow control valve in association with a throttle type
temperature compensating device. In the compensatory spool, the pressure
is sensed to the bottom of the spool through a passage drilled in its body,
instead of having a separate sensing passage.
• In order to attain balance position, the compensatory spool moves and
adjusts the area of metering orifice.
• This gives necessary pressure compensation.
• Also instead of using the usual throttling arrangement, a cup shaped device
with “V” notches is used for better control on flow rate. This cup is held by
a small spring against the shoulder of an aluminium alloy rod which
extends through the cup into the oil flow. It is set for a particular flow rate.
As temperature of oil rises, the oil becomes a little thinner and tend to flow
faster through.
• However, the increased temperature also causes the Aluminium rod to
expand and close the throttle opening to compensate for the change in oil
viscosity. Thus even with the thinner oil, the flow rate stays essentially the
same.
• A check valve is frequently incorporated to allow relatively unrestricted
reverseflow.
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 Non-compensated flow control valves
• used when the system pressure is
relatively constant and motoring
speeds are not too critical
• flow through an orifice remains
constant if the pressure drop across
it remains the same
• the rate of flow through an orifice
depends on the pressure drop
across it
https://youtu.be/slr-gT_x1NA

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