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Advanced Hydraulic Valves and Their Applications

Advanced Hydraulic Valves and Their Applications


Advanced Hydraulic Valves and Their Applications

Valves used in advanced hydraulic systems; It plays a critical role in applications requiring precise control, quick response, and high accuracy. These valves are widely used in automation, robotics, test systems, heavy industrial machinery, and the aerospace sector.

Proportional valves, servo valves and electronically controlled hydraulic systems are discussed in detail below.

  1. Proportional Valves

Proportional valves are valves that adjust the flow rate or pressure of hydraulic fluid in proportion to the electrical signal being sent. Proportional control allows for smoother movements, more precise adjustments, and energy efficiency in the system.

1.1 Working Principle

The operation of proportional valves relies on three key components:

  1. Control signal: An electrical signal, usually in the range of 0–10 V or 4–20 mA.
  2. Electromagnet (solenoid): Moves the valve gate to a specific position according to the electrical signal.
  3. Hydraulic output: Proportional flow or pressure is provided depending on the valve's position.

Thanks to this structure, the valve opens as the input signal increases and closes as it decreases. Thus, a linear control is achieved.

1.2 Characteristics of Proportional Valves

  • Linear control: The output is proportional to the input signal.
  • High precision: Provides low margin of error in applications requiring fine tuning.
  • Gradual and smooth movement: Reduces vibration in mechanical parts.
  • Wide control range: Allows for different speed, flow and pressure settings.
  • Flexible control options: Can be managed by PLC, PID controller or joystick.

1.3 Types of Proportional Valves

  1. Proportional Flow Valves: Adjust
     flow proportionally in applications like cylinder speed control.
  2. Proportional Pressure Valves:
    Keeps system pressure at the desired level; used for safety, regulation and precise pressure control.
  3. Proportional Directional Valves: These
     are valves that change the direction of fluid proportionally; critical in robotics and motion control.

1.4 Advantages of Proportional Valves

  • High precision motion control
  • Energy Efficiency
  • Smooth acceleration/deceleration
  • Remote adjustment
  • Dynamic and flexible application options
  1. Servo Valves

Servo valves are valves with higher precision and faster response time than proportional valves. They respond precisely to even very small electrical signals and are often  used in applications requiring high dynamic performance.

2.1 Working Principle

The working structure of servo valves includes feedback mechanism:

  1. The control signal is sent.
  2. The electromotor/solenoid positions the needle valve or gate according to the signal.
  3. The hydraulic flow is adjusted according to this position.
  4. The feedback mechanism maintains the target value by constantly controlling the position of the valve.

Thanks to this mechanism, servo valves offer micro-level precision.

2.2 Characteristics of Servo Valves

  • Highest sensitivity (micron level)
  • Extremely fast response
  • Feedback-controlled operation
  • Stable movement even at low speeds
  • Quick adaptation to dynamic load changes

2.3 Types of Servo Valves

  • Proportional servo valves (advanced precision proportional control)
  • On–Off servo valves (high speed–low precision)
  • Servo valves with routing (high precision routing)
  • Double-acting servo valves (systems requiring two-way control)

2.4 Uses of Servo Valves

  • CNC machines
  • Industrial robots
  • Aircraft hydraulic systems
  • Precision testing equipment
  • Advanced automation systems
  • High-speed production lines
  1. Electronically Controlled Hydraulic Systems (EKHS)

Electronically controlled hydraulic systems are modern systems that optimize hydraulic power transmission with sensors, control units (PLC, ECU) and electronic valves. They enable more precise, efficient and dynamic control of hydraulic performance.

3.1 Key Components

  1. Sensors
  • Pressure sensors
  • Flow sensors
  • Position sensors
  • Temperature sensors
  1. Electronic Control Unit (ECU/PLC)
  • Processes sensor data
  • Decides and sends signals to the valves
  • It can use algorithms such as PID, fuzzy logic, adaptive control
  1. Proportional/Servo Valves

It allows for dynamic and precise control of hydraulic flow.

  1. Pumps and Motors

Variable displacement pumps in particular  offer high energy savings with electronic control.

3.2 Advantages of Electronically Controlled Systems

  • Precise position and speed control
  • Energy optimization and low consumption
  • Reliable response at high speed
  • Fault monitoring and fault detection
  • Remote control and automation integration
  1. Dynamic Modeling and Simulation of Fluid

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  • 4.1 Mathematical modeling in hydraulic systems
  • 4.2 Linear and non-linear modeling approach
  • 4.3 Simulation software (Simulink, Amesim, Automation Studio, etc.)
  • 4.4 Model validation and testing processes
  • 4.5 Analysis of dynamic system responses