DIY hydraulics

Netherlands-based AMCA Hydraulic Fluid Power has designed a self-build modular concept for its hydraulic proportional load-sensing directional control valves. The build concept is designed to provide distributors, OEMs and end users with a flexible and cost-effective solution that will suit a wide range of applications.

The AMCA self-build modular concept is available for advanced proportional valves (APV) sizes 16 and 22. Flexibility is provided through the selection of connection blocks with a range of optional functions that can be ‘built’ onto the valve in order to suit each user’s requirements.

Figure 1: Options for inlet section.

The APV-16 series provides a maximum flow up to 120 L/min and the APV-22 series provides up to 330 L/min. The maximum operating pressure is 420 bar. Operating controls are available in any combination - electrical, manual and hydraulic.

Control methods, including flow, pressure and primary and secondary safety functions, can all be configured separately. Each method can be changed without having to dismount the complete valve block. This means that distributors, OEMs and users can easily carry out this procedure, resulting in a decreased need for stock on hand and providing flexibility while maintaining technical performance.

Self-assembly of the valve is quick as all the necessary valve-block configurations are based on pre-tested modular valve-block components. The blocks are mounted on top of the control sections and onto the inlet and stacked valve end plate. The spring and end caps of the APV are configured to make block changes easy for the user. All components are packed in standardised box sizes for easy transportation.

APV blocks are built up with basic build program parts (BPPs), functional interchangeable parts (FIPs) and service parts (SPs). Using the structured and easy-to-follow assembly instructions, different functional parts can be mounted and the valve block can be built from its inlet section across the different spool sections and, finally, to the correct end plate.

The user has the choice of different inlet sections suitable for fixed displacement pumps, load-sensing (LS) pumps or constant pressure networks. If options such as a pump unloading function or an electrical proportional pressure relief valve are required, they can be easily mounted on the appropriate type of inlet section as shown in Figure 2.

Figure 2: Spook kit for preassembled valve block.

The preassembled spool section contains the standard two-way compensator, shuttle valves and all necessary plugs and sealings. Depending on the control method employed, different cartridges and a large choice of build program spool types are available. The spools are already preassembled with the spring package as shown in Figures 3, 4 and 5.

Figure 3: Control methods on spool section.

Figure 4: Assembly of standard build program parts.

Figure 5: Connection blocks as standard build program parts.

Figure 6 shows the available connection blocks which constitute standard-build program parts. They are supplied in the following formats:

• Basic, with user port connection only;
• Secondary safety functions LS reliefs and LS ports and A/B standard;
• Primary and secondary safety functions, LS reliefs and LS ports on A/B standard.

Figure 6: Assembly of the anti-saturation function.

There is an option to assemble full-flow port reliefs, shock/anti-cavitation or just anti-cavitation valves. It is also possible to design a special connection block with the functions needed by the end user, such as piloted check valves, counterbalance valves or 2/2 way valves.

There are three different end plates available, suitable for manual, electrical or hydraulically operated valve blocks. An internal reducing valve for pilot-pressure supply is included with the build program end plates for electrical or hydraulic valve blocks.

Because build program components are already pretested, the end test is as simple as the assembly of the valve blocks, just a short final check to ensure the self-assembled sections are leak free.

Additional features of the APV valves include:

• Several inlet plates types available for fixed and variable displacement pumps and constant pressure networks;
• Different spool types up to 120 L/min (APV-16) and 330 L/min (APV-22), in combination with simultaneous control;
• ATEX solenoids;
• Standard seawater-resistant valves;
• Easy maintenance, as all essential components can be dismantled from outside the block without disassembling valve sections;
• The modular construction makes it easy and cost effective to integrate special user functions into a special connection block mounted onto the standard valve block;
• The compact sandwich design makes it suitable for mobile hydraulic applications; and
• The anti-saturation function for load-independent control of several control valves, even under working conditions where there is insufficient pump flow.
• Simultaneous operation of user functions is dependent on sufficient pump flow. If one user requires more flow, one of the others could fail. Therefore a feature has been developed, shown in Figures 7 and 8, which will reduce the flow for every control section, even in pre-compensated valves, ensuring that every user can keep working at the same time.

Figure 7: Compensator types available.

Figure 8.

The AMCA modular build concept for advanced proportional valves (APV) is being distributed by K-One Fluid Power which has established inventory levels and assembly procedures to meet the varying build and delivery requirements of the Australian and New Zealand market.

The concept is being introduced to the hydraulic industry in Australia and New Zealand by K-One Fluid Power.