The Ultimate Guide to Mechanical Valves

Introduction

A mechanical valve is a type of valve that does not require electrical power to operate. It controls the direction, pressure, or flow rate of a fluid—either liquid or gas—through physical actions such as pressing, rotating, or pushing. Mechanical valves are classified as non-automatic control components.They are widely used in pneumatic and hydraulic systems to control equipment movements or switch between different processes.

Types of Mechanical Valves in Pneumatic and Hydraulic Systems

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Mechanical Valve vs. Solenoid Valve

Control Method

Mechanical Valve: Operated without the need for external signals. It is controlled through mechanical actions such as manual levers, push buttons, or rotation, directly affecting the valve’s opening and closing. It relies on manual or mechanical operation.

Solenoid Valve: Requires an external electrical signal. When the solenoid coil is energized, it generates a magnetic field that drives the valve spool to move, enabling automatic opening and closing. It supports remote control and automation.

Cost

Mechanical Valve: Simple structure, low manufacturing cost, suitable for applications with limited budget or low automation requirements.

Solenoid Valve: More complex structure with electromagnetic components, relatively higher cost, but prices are gradually decreasing with technological advancements.

Maintenance Requirements

Mechanical Valve: Maintenance is relatively simple, with clear structural components and obvious causes of failure,making disassembly and repair convenient. However, frequent manual operation may lead to faster wear and tear.

Solenoid Valve: Maintenance is more complex and requires specialized knowledge. It is necessary to check for faults in the electromagnetic coil and electronic components regularly.The electrical parts have higher environmental requirements and need periodic inspection of coils and circuits.

Application Comparison

Mechanical Valve: Cannot be remotely controlled and has limited operation. Suitable for systems that require manual control or on-site operation, harsh environments, or situations without a power supply. It offers relatively high reliability and durable construction.

Solenoid Valve: Widely used in automated production lines, remote control systems, and complex process flows. It offers fast response and precise control, making it ideal for integrated control systems.

Working Principle of a Mechanical Valve

Valve Actuation Methods

Mechanical valves are actuated through physical mechanical motion and do not rely on an external power source. The operating methods include:

Push-button type: When the button is pressed, the internal valve spool moves, changing the fluid passage.

Handle operation: Pushing or pulling the handle shifts the valve spool to achieve directional control.

Rotary knob type: Rotating the knob controls the opening, closing, or switching of the flow direction.

Mechanical linkage actuation: In automated machinery, components such as cams or sliders directly trigger the valve operation.

These actuation methods are suitable for environments without electricity or for applications where high control precision is not required.

Flow Direction Control

Mechanical valves control the flow direction of fluids or gases through their internal structures, such as the valve spool, slider, and flow channels. Depending on the valve type (e.g., 2/2-way, 3/2-way, 5/2-way, etc.), the following control functions can be achieved:

Controlling the on/off flow from the inlet to the outlet

Switching flow direction between multiple channels

Reversing fluid flow or closing it off in a middle position

Flow direction control is achieved by changing the state of internal passages through manual or mechanical operation, resulting in different output pathways.

Sealing Mechanism

To prevent leakage and ensure proper operation, mechanical valves are equipped with various internal sealing structures, including:

Rubber or elastomer seals (such as O-rings and gaskets)

Metal-to-metal seals, achieved through precisely machined contact surfaces

Spring-loaded seals, which use spring pressure to keep the sealing elements tightly pressed against the sealing surfaces

Good sealing performance is essential for preventing fluid leakage and maintaining system pressure, and it is especially critical in high-pressure or high-frequency operation scenarios.