Hydraulic valve manifold components and design considerations?

A hydraulic valve manifold that integrates or combines a plurality of selected hydraulic control valve members mounted on the same metal block body to form an assembly with predetermined control functions.

hydraulic valve manifold

Its structure divides it into bar blocks, small plate blocks, cover plates, and plywood. According to its use, it divides into many forms such as valve mounting base plates, pump valve blocks, logic valve blocks, stacked valve blocks, special valve blocks, collector drains, and connecting blocks.

First, the composition of hydraulic valve manifolds

In the hydraulic system, the hydraulic valve manifold consists of the body of the valve manifold, the hydraulic valve mounted on the body of the valve manifold, pipe fittings, accessories and other components.

1、Valve block body

Valve block body is the other hydraulic components of the mounting carrier, but also the oil circuit connected to the channel body, is the key component of the integrated hydraulic system. General use of rectangular shape, the material is usually aluminum or malleable cast iron.

hydraulic valve manifold

The valve block body distributes hydraulic valve-related mounting holes, oil holes, connecting screw holes, positioning pin holes, as well as common oil holes and connection holes. This ensures correct alignment of the holes without interfering with the process, sometimes necessitating the addition of further holes.

2、Hydraulic valve

Hydraulic valves are typically standard parts, including various types such as plate valves, cartridge valves, and stacked valves. They mount onto the valve block body using connecting screws to achieve the hydraulic circuit’s control function.

3、Fittings

Used for external piping and valve block connection. Various types of valves and valve blocks compose the hydraulic circuit to control hydraulic cylinders and other actuators, as well as manage oil input, output, drainage, etc., requiring connection to external pipelines to function.

4、Other accessories

Including piping connection flange, process hole plugging, oil circuit sealing ring and other accessories.

Second, the main points of the design of hydraulic valve manifolds

1. General principles

The design of the hydraulic cube shall strictly follow the general principles of smallest possible total volume of the valve block, clear and concise direction of the internal oil pipeline, small pressure loss of the oil pipeline, and compact assembly for easy operation.

2. Material selection

Different materials determine different pressure levels, according to the use of pressure for a reasonable selection of materials:

You can use cast iron HT20 to HT40 for working pressures less than 6.3 MPa.Casting cast iron parts in large quantities reduces man-hours and improves efficiency, especially for standardized valve blocks.

For working pressures between 6.3 MPa and less than 21 MPa, you can use aluminum alloy forgings, 20 forging steel, or Q235. The good welding performance of mild steel makes it especially suitable for welding non-standard hard pipes, which many valve blocks frequently require welding.
Working pressure ≥ 21MPa, the choice of 35 forging steel, forging directly after machining or machining after tempering treatment HB200-240 (general high-pressure valve block, often flaw detection, machining and heat treatment cycle).

hydraulic valve manifold

3. Component arrangement
The valve block’s top surface serves as the main mounting surface, while the bottom surface functions as the fixed surface where valves are typically not installed. It is generally recommended not to drill process holes or connect external pipelines on this bottom surface. However, if necessary, oil ports can be processed on the bottom surface.

Install components that require frequent adjustment, such as relief valves, throttle valves, and speed control valves, on accessible side or top surfaces. Preferably place directional valves on the top surface. Mount other components, such as check valves that do not require frequent adjustment, on less accessible surfaces.After installation, keep the spool of each valve as horizontal as possible.

Third, the hydraulic valve manifold design note

Part I

  • The determination of the overall direction of the oil circuit is critical, otherwise it will lead to many unnecessary changes at a later stage. The overall layout of the oil circuit is based on the principle of compactness and convenience of the entire pumping station.
  • In advance, you should select valve block and external piping interface components (pipe joints or flanges), considering the external dimensions, which will impact the determination of the overall size of the valve block.
  • The maximum side length of the valve block should not be more than 600mm, and the number of 2-way cartridge valve inserts should not exceed 8. When there are more than 8 inserts, you should break it down into several valve blocks, connect them with each other by bolts, and seal the connecting apertures at the bonding surface with O-ring to form an integral valve block group.

hydraulic valve manifold

Part II

  • You must clearly mark all external oil ports and inspection ports on the valve block with corresponding labels.These labels should match the markings on the hydraulic schematic diagram. To ensure that the sealing performance of the O-ring is not compromised, place steel seals used for marking at least 6mm away from the orifice.
  • For larger valve blocks, it is necessary to have a lifting screw port. Ideally, the lifting screw port should be positioned on the top surface of the block assembly. However, it can alternatively be located on the side to ensure that the block assembly does not require overturning during the lifting process. This port is specifically designed for installing a lifting ring screw, which must adhere to the standard GB825-88.
  • To secure the valve block, the bottom should feature mounting bolt holes. Small valve blocks may have through holes, while large ones typically have blind holes. Generally, there are 4 holes for small valve blocks and 6 or more for larger ones, evenly distributed according to relevant design standards. Depending on specific needs, you can mount the valve block on top of tanks, pump outlets, workbenches, or hydraulic cylinders.Mounting can be direct or via welding with profile brackets for support.
  • The main stage orifice commonly connects the external oil port using a flange. Alternatively, oil ports with a diameter of 25mm or less can use a threaded connection method for their connection. The pilot orifice is indeed suitable for such a threaded connection.

hydraulic valve manifold

Last part

  • Removable means such as screw plug flanges should block process orifices to enable cleaning, washing, and inspection.In confined spaces, you can seal orifices with diameters up to 12mm using ball rising plugs.
  • When installing conventional industrial solenoid valves or stack valves (6, 10, 16, and 25 mm in diameter) on a valve block, use connecting bolts with a minimum grade of 12.9 to ensure robust fastening.
  • Detection ports are essential for monitoring hydraulic circuit parameters and diagnosing faults, equipped with the main stage and pilot orifices.Typically, these detection ports should feature a quick-connect function for pressure measurement connectors.
  • When dealing with differences in pipeline and valve block orifice sizes, using reducer fittings is a practical choice.
  • The nameplate installation position should reserve a conspicuous location in the valve block.

 

Of course, Zhuo Yi Control Technology Co., Ltd. specializes in hydraulic valve manifold business, you can お問い合わせ for customized hydraulic manifold.

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