Industrial Vehicle Technology - Off-Highway Annual 2026
Precise load control
2025-12-01 12:45:00
Integrated valve simplifies mobile hydraulics
WANDFLUH’S ALL-IN-ONE VALVE INTEGRATES MULTIPLE HYDRAULIC FUNCTIONS TO DELIVER PRECISE LOAD CONTROL IN MOBILE MACHINERY APPLICATIONS
In mobile hydraulics, the precise control of lifting and lowering movements plays a decisive role in the efficiency, safety, and durability of mobile machinery. Whether in agriculture, construction, or materials handling, the hydraulic movement of heavy loads requires systems that combine performance, controllability, and safety. The so-called all-in-one solution represents a compact and technically advanced alternative to conventional hydraulic valve circuits.
Hydraulic challenges in mobile machinery
In mobile hydraulic systems, lowering movements are typically controlled via proportional valves in a bypass circuit. To prevent exceeding maximum safety speeds, load-independent flow control valves limit the flow rate. However, when higher operating speeds and greater productivity are desired, the hydraulic circuit becomes more complex.
Agricultural machinery provides a typical example: a wide range of attachments can be hydraulically lifted, rotated, or transported. These implements are connected to the machine via hydraulic hoses and are powered by cylinders and hydraulic motors. Similar requirements exist in forklifts, lifting platforms, cranes, and elevators, where heavy loads must be moved as smoothly, safely and precisely as possible.
Proportional flow control valves
A key component in conventional systems is the proportional flow control valve. For the holding function, a leak-free 2/2-way seated valve is typically used. To lower a load, this valve opens, and the oil flow is directed through a proportionally adjustable throttle or flow control valve. The proportional solenoid enables sensitive and precise control of the lowering movement.
Unlike simple throttle valves, flow control valves include an integrated pressure compensator, which ensures a loadindependent lowering speed. This feature is particularly critical in systems with multiple cylinders operating in parallel. Proper coordination between flow rate, control precision, and damping is essential. Insufficient coordination can lead to oscillations – known as the bouncing effect – where the load vibrates or rebounds during lowering.
To avoid this effect, proportional throttle valves or flow control valves with an integrated damping system are used. These combinations provide stable motion sequences, enhance operational safety, and protect mechanical components from shock loads.
The all-in-one valve concept
The all-in-one solution combines several of these hydraulic functions within a single valve body. This approach not only simplifies the hydraulic system architecture but also reduces the number of components, seals, and potential leakage points.
The valve is designed to close seat-tight in the de-energized state, securely holding the load in position. When control current is applied, the valve opens proportionally, enabling sensitive, load-independent lifting and lowering. The lowering speed remains constant because the integrated regulator automatically adjusts the flow rate to changing pressure conditions.
By integrating several functions, the allin-one valve replaces conventional components such as loadholding valves, flow restrictors, or speed limiters. The resulting hydraulic schematic is more compact and efficient, reducing installation effort, space requirements and system costs.
Functional advantages
Combining seat valve and proportional control functionality provides multiple technical benefits. The seat-tight design prevents creeping or sinking of the load, even over long idle periods. The proportional solenoid allows fine control of movement speed. The internal pressure compensation maintains constant speed under varying loads. Eliminating additional throttling points reduces energy losses. Integrating multiple functions minimises space and component count. The optimised valve design prevents the bouncing effect during lowering.
These properties make the all-in-one valve especially suitable for applications that require high precision, compact dimensions and efficient energy usage.
Electronic control and system adaptation
For optimal performance, the all-in-one valve can be combined with various amplifier and control electronics. Integration into existing machine control systems is straightforward thanks to standardized interfaces, allowing flexible adaptation to different hydraulic architectures.
Depending on the application, parameters such as opening characteristics, control response, and damping behavior can be individually configured. This makes the valve equally suitable for highly dynamic applications, such as in construction machinery, for applications requiring maximum positioning accuracy, such as in agricultural or materials-handling equipment.
The all-in-one valve technology provides mobile hydraulics with a compact, efficient, and precise solution that integrates multiple hydraulic functions into a single component. It enables constant, load-independent cylinder movement, simplifies system architecture, and increases operational safety.
By combining seat-tight load holding, proportional flow control, and integrated pressure compensation, the concept offers a technically advanced response to the growing demands placed on modern off-highway machinery – particularly regarding efficiency, compactness and dynamic performance.
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Precise load control
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