Pilot step with ball-cone seat

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a pilot-operated pressure control valve and a shock absorber. BACKGROUND OF THE INVENTION

[0002] Valves for controlling hydraulic shock absorbers exist in various designs. In addition to directly controlled proportional valves, known from EP 3 591 273, for example, pilot-operated pressure control valves are also used, such as those known from WO 2009 157 841 A1 or WO 2020 182 358 A1.

[0003] In such pilot-operated pressure control valves, the oil flow to be regulated is guided through a main stage and throttled there to a greater or lesser extent. However, the main stage is not actuated directly by a magnetic drive, but rather by a second valve stage, the so-called pilot stage, which has a pilot stage valve. The pilot stage valve controls the pressure on at least one side of the main stage valve and is thus able to generate fluid-dynamic forces in the main stage that actuate the main stage valve. The pilot stage valve itself is adjusted by an electromagnetic actuator. One advantage of this multi-stage design is that high actuation forces can be generated in the main stage using relatively small electromagnetic actuators. The valves are therefore comparatively robust against hydraulic disturbance forces and are very compact.

[0004] For technical reasons, variant design plays an important role in the field of damper control valves. The control valve function is designed and coordinated with the damper. Different damper types and applications require different damper configurations and, therefore, corresponding pressure control valve variants.

[0005] An important parameter in tuning the damper, for example, is the opening pressure of the control valve. This determines the maximum damping force and thus the damper's spread. The opening pressure is determined by the design of the pilot stage. In pilot stage valves with a seat design, as is the case in the documents cited above, the opening pressure can be adjusted via the force balance of the magnetic force and, if necessary, a spring force of the actuator and the pressure force of the fluid. To achieve different opening pressures, the seat diameter and thus the pressure force are usually varied.

[0006] The pilot valves of conventional pressure control valves are generally formed by complex components that seal each other with flat surfaces. This places high demands on the surfaces and shape deviations of the valve elements, making manufacturing correspondingly complex. Furthermore, the valve elements are so integrated into the overall design of the control valve that varying the opening pressure based on the seat diameter is difficult to achieve.

[0007] Such pilot-operated pressure control valves are described, for example, in the documents US 9,915,276 B2, US 8,662,109 B2 and US 2019 / 0217840 A1. SUMMARY OF THE INVENTION

[0008] The object of the invention is to provide a cost-effective pressure control valve with reduced manufacturing costs. It is also an object of the present invention to provide a corresponding shock absorber.

[0009] The problem is solved by a device having the features of the independent claims. Preferred embodiments and further developments are specified in the dependent claims.

[0010] The pressure control valve according to the invention comprises a pilot stage valve with a ball valve body and a conical seat as the valve seat for the ball valve body. In contrast to seat valves with flat sealing surfaces, such a ball-conical seat pairing places lower demands on the quality and precision of the sealing surfaces or surfaces that create the valve seat. This allows the manufacturing effort of the pilot stage valve to be reduced and a cost-effective pilot stage valve to be provided, while simultaneously keeping the dispersion of the parameters of the pilot stage valve or pressure control valve to a minimum. The ball valve body is a completely spherical body, preferably according to quality class G5 (according to DIN 5401). The dimensional and form tolerance is accordingly a maximum of 0.25 µm.The diameter of the ball valve body is preferably in the range between 1 and 10 mm and is, for example, 1, 2, 3, 5, 8 or 10 mm, whereby each of the stated values ​​can also represent an upper or lower limit of the stated value range. The opening diameter of the conical seat is preferably in the range between 1.5 mm and 4 mm and is, for example, 1.5, 2.0, 2.5, 3.0, 3.5 or 4.0 mm, whereby each of the stated values ​​can also represent an upper or lower limit of the stated value range. The conical angle (opening angle) of the conical seat is preferably in the range between 100° and 140° and is, for example, 100°, 110°, 120°, 130° or 140°, whereby each of the stated values ​​can also represent an upper or lower limit of the stated value range.

[0011] According to the invention, the pilot stage valve further comprises a guide section for guiding the ball valve body when it lifts off the valve or cone seat or when the pilot stage valve opens. The guide section is accordingly located downstream of the cone seat and / or has a cylindrical inner wall that runs coaxially with a valve axis of the pilot stage valve or the central axis of the pressure control valve. This makes it possible for the valve body not to be actively guided or positively guided, for example by an actuating element of an actuator, and a corresponding cross-assembly or cross-module component consisting, for example, of the actuating element and the valve body can be avoided. This simplifies the mechanical interaction between the pilot stage and the actuator and opens up more degrees of freedom for the (structural) design of the actuator.The pilot stage valve is then preferably actuated by the actuator only by impact or only by contacting the actuating element on the ball valve body.

[0012] The inner diameter of the guide section is correspondingly identical to the diameter of the ball valve body plus a clearance (relative to the diameter), preferably in the range between 0.01 and 0.1 mm, and is, for example, 0.01, 0.02, 0.03, 0.05, 0.08, or 0.1 mm, whereby each of the stated values ​​can also represent an upper or lower limit of the stated value range. The length of the guide section above the conical seat is preferably in the range between 3 and 30 mm and is, for example, 3, 5, 8, 10, 15, 20, or 30 mm, whereby each of the stated values ​​can also represent an upper or lower limit of the stated value range.

[0013] The pilot stage valve preferably has a module body which provides or has the conical seat and the guide section and which is particularly preferably formed in one piece. Accordingly, in the simplest case, the pilot stage valve consists precisely of the ball valve body and the module body, i.e. of two one-piece components. Preferably, the guide section has no mechanical safeguard (such as a lug or notch on the inside of the guide section) to prevent the ball valve body from being removed from the guide section. This simplifies the assembly of the pilot stage valve. Preferably, the actuating element of the actuator provides a safeguard to prevent the ball valve body from being removed from the guide section when the pressure control valve is installed.

[0014] Preferably, the pilot stage valve or its module body upstream of the conical seat has a receiving section for the optional or selective reception and fastening of a fluid component, for example a throttle, in or on the pilot stage valve. The receiving section is preferably designed as a recess and / or cylindrical recess that runs coaxially to the valve axis or central axis. The inner wall of the recess preferably has a thread or internal thread for mounting the fluid component, which can then be installed in the pilot stage valve with little effort. Different throttles can also be provided depending on the application, which facilitates the creation of variants.Alternatively, the inner wall of the receiving section designed as a recess can also be designed as a smooth, cylindrical surface, so that a selected fluid component can, for example, be pressed into the recess or inserted and then fastened in the pilot stage valve or its module body, for example by welding or soldering. Such a throttle limits the flow through the pilot stage when the pilot stage valve is (fully) open. If the fluid component is designed as a throttle, the throttle cross-section is preferably in the range between 0.01 and 1 mm 2< and is, for example, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5 or 1 mm 2< , whereby each of the stated values ​​can also represent an upper or lower limit of the stated value range.

[0015] The pilot stage valve preferably has a fail-safe function. For this purpose, the pilot stage valve comprises a fail-safe valve seat at the end of the guide section opposite the cone seat, and preferably a spring element which presses the ball valve body into the fail-safe valve seat. The ball valve body therefore sits securely in the fail-safe valve seat when the actuator is de-energized, i.e. without actuator forces, for example in the event of a power failure. The fail-safe valve seat thus forms a second, additional valve seat, which is preferably also designed as a cone seat. The spring element is supported within the cone seat. In this case, the guide section is not completely open on the side opposite the cone seat, but merely has an axial opening in the end face of the pilot stage module or on the valve axis for actuation by the actuator. The pilot stage valve is therefore safely opened or closed when de-energized.Partially open with a defined opening cross-section that is smaller than the maximum opening cross-section of the pilot stage valve. Preferably, the pilot stage module has bypass openings and / or the ball valve body does not completely seal the fail-safe valve seat. The fail-safe valve seat preferably has a polygon as the axial through- or valve opening, in particular a regular polygon, for example an (equilateral) triangle, rectangle, square, hexagon, or octagon.

[0016] The pilot stage module preferably has a failsafe component that has the failsafe valve seat and is preferably designed as a cap or sleeve for the module body. Furthermore, in this case, no radial outflow openings are provided in the pilot stage valve or its module body, and / or these are closed by the failsafe component.

[0017] In a preferred embodiment, the pressure control valve has a plurality of functional modules, namely at least one pilot stage module and one actuator module, i.e. at least two functional modules.

[0018] A functional module is generally an assembly, more precisely a modular assembly of the pressure control valve, which (fully) provides a specific functionality or the functionality intended for this assembly or functional module and which comprises all or at least all of the essential structural components for this functionality. Functional modules are thus structurally and functionally different or distinct assemblies of the pressure control valve, which, in the assembled pressure control valve, preferably do not have any components that span multiple assemblies or modules. Thus, in the simplest case, a given functionality in the pressure control valve is provided exclusively by the respective or precisely one functional module.

[0019] The pilot stage module of the pressure control valve accordingly implements (exactly or at least) the functionality of the pilot stage in the pressure control valve, which serves for the fluid-dynamic, usually hydraulic, pilot control of the pressure control valve or its main stage, and / or contains all or part of the components required for this, such as a pilot stage valve. Accordingly, in the simplest case, the functionality of the pilot stage in the pressure control valve is provided exclusively by the pilot stage module. In the simplest case, the pilot stage module consists precisely of the pilot stage valve.

[0020] The actuator module of the pressure control valve implements (exactly or at least) the functionality of the actuator in the pressure control valve, which serves to actuate the pilot stage or the pilot stage module or the pilot stage valve of the pilot stage module, in particular a valve body of the pilot stage valve, and / or contains the necessary components, such as a coil and a magnet armature, and optionally a spring element. Accordingly, in the simplest case, the functionality of the actuator in the pressure control valve is provided exclusively by the actuator module.

[0021] Advantageously, the pilot stage module and the actuator module, preferably all functional modules of the pressure control valve, are each designed as pre-assembled or prefabricated modules or assemblies. In other words, all components of a functional module are preferably integrated into or into a (pre-assembled) assembly. Likewise, advantageously, functional modules in the pressure control valve that are directly and firmly connected to one another are firmly connected to one another via only one mechanical interface and / or with only one joining method (e.g., by pressing, welding, soldering, etc.). This simplifies the assembly or final assembly of the pressure control valve.

[0022] Preferably, the pilot stage module and the actuator module are firmly connected to one another via a press connection, preferably precisely and / or exclusively via a press connection, and are arranged directly adjacent to one another. Such a press connection allows, in addition to a simple and sufficiently secure attachment of the pilot stage module in or on the actuator module, an adjustment or fine-tuning of the position of the pilot stage module and the actuator module relative to one another, for example, during assembly and / or after assembly. A press connection creates a force or frictional connection along corresponding pressing surfaces.

[0023] The actuator module preferably has an actuator with an actuator axis, meaning that the actuation (of the pilot stage valve) occurs (by a reciprocal movement) along a straight path. Accordingly, the actuator is preferably a linear actuator.

[0024] Furthermore, to provide the exact press connection with the pilot stage module, the actuator module has one or exactly one preferably cylindrical and / or radial, coaxial, collinear or concentric press surface directed towards the actuator axis, wherein the press surface is preferably completely continuous, but may optionally also be divided into several partial surfaces or have interruptions. This press surface preferably creates exactly one press connection. This press surface preferably forms the (inner or inward-facing) upper or outer surface of a recess in the actuator module, wherein the recess encompasses the actuator axis and is preferably cylindrical or substantially cylindrical and / or coaxial, collinear or concentric with the actuator axis. The actuator axis is preferably simultaneously a symmetry and / or central axis of the (entire) actuator module or the actuator.

[0025] The pilot stage module preferably has a pilot stage valve that can be actuated along a valve axis, or rather the valve axis, and which is preferably a seat valve. In the simplest case, the pilot stage valve has a valve body that is displaceable along the valve axis and opens and closes the pilot stage valve when the valve body, for example, is lifted from a corresponding valve seat or retracts into the valve seat. In other words, when the pilot stage is actuated, the actuator module causes and / or permits a generally reciprocal and / or linear movement of the valve body along the valve axis.

[0026] Furthermore, in order to create the or precisely one press connection with the actuator module, the pilot stage module has a preferably cylindrical and / or radial, coaxial, collinear or concentric press surface that corresponds to the press surface of the actuator module and is directed away from the valve axis. The press surface is preferably completely continuous, but can optionally also be divided into several partial surfaces or have interruptions, which then preferably correspond to corresponding partial surfaces or interruptions of the press surface of the actuator module. This press surface preferably creates precisely one press connection. This press surface preferably forms the (outer or outward-facing) upper or outer surface of the pilot stage module, wherein the entire pilot stage module is preferably cylindrical or substantially cylindrical and / or rotationally symmetrical (optionally apart from radial fluid openings).The valve axis preferably forms a symmetry and / or central axis of the (entire) pilot stage module. The pilot stage module thus forms a cartridge that corresponds to the above-described recess in the actuator module and is partially or completely received therein, so that the corresponding pressing surfaces create a press connection between the actuator module and the pilot stage module.

[0027] Accordingly, in the assembled pressure control valve, the actuator axis of the actuator module and the valve axis of the pilot stage module preferably coincide to form a common central axis of the pressure control valve, so that the actuator module or the actuator of the actuator module can actuate the pilot stage valve of the pilot stage module along this central axis. Due to the press connection according to the invention, the adjustment or fine adjustment described above can then be carried out along this central axis, and thus the axial position of the actuator module and pilot stage module relative to one another can be adjusted or finely adjusted along the central axis. This allows for variation (for example with regard to a spring and / or magnetic or actuator force and / or an opening pressure) in a batch of several pressure control valves orto reduce during series production, for example, with regard to an air gap and / or a remanence distance of a magnetic armature in the actuator, particularly when the actuator closes the pilot stage valve or when the valve body in the pilot stage valve strikes the valve seat. The fluctuations in the opening pressure within a batch are preferably less than 10%, particularly preferably less than 5%.

[0028] The actuator module generally has an actuating element with which the actuator module actuates the pilot stage valve of the pilot stage module. In the simplest case, the actuating element is the magnet armature itself, which is generally made entirely of magnetic material, or a preferably non-magnetic plunger, which is then, for example, firmly connected to the magnet armature or forms a one-piece component with the magnet armature, which is, for example, designed to execute reciprocal and / or linear movements along the actuator axis or the common central axis. In this case, the actuating element advantageously (only) strikes the valve body of the pilot stage valve of the pilot stage module when or to actuate the pilot stage valve. In other words, the actuating element is advantageously (only) located on the valve body of the pilot stage valve of the pilot stage module.(exactly) in contact with the valve body of the pilot stage valve of the pilot stage module, particularly when the valve body closes the pilot stage valve or when the valve body strikes the valve seat. There is therefore no fixed mechanical connection between the actuating element and the valve body, i.e. there is no forced guidance of the valve body by the actuating element of the actuator module. A cross-module component (between the actuator module and the pilot stage module) is accordingly avoided or does not arise. The valve body of the pilot stage valve is advantageously non-magnetic or magnetically non-conductive.

[0029] Preferably, the pilot stage module and actuator module are firmly connected to one another exclusively via the press connection according to the invention. This simplifies the assembly of the pressure control valve and simultaneously allows adjustment or readjustment during or at a time separate from the assembly of the pressure control valve.

[0030] The modular design of the pilot stage and actuator of the pressure control valve, in the form of a pilot stage module and actuator module, not only avoids components across assemblies or modules, but also simplifies the (preferably only) mechanical interface (here, a press connection with corresponding press surfaces on the pilot stage module and actuator module) for creating the fixed mechanical connection between the pilot stage module and actuator module. Therefore, for example, a functional module can easily be exchanged for a variant of it. In other words, the pressure control valve according to the invention facilitates the creation of variants orDesigning different pressure control valves with different parameters, since this often requires adaptation to only one functionality, and then only the corresponding, i.e., a single functional module, needs to be replaced with a variant of it, while the remaining components and / or functional modules of the pressure control valve remain unchanged and are thus identical parts. Accordingly, the interface for attaching the functional module also preferably remains unchanged for variants of a functional module. For example, a pilot stage module with a different opening cross-section or valve seat diameter can be used to change the opening pressure and / or the pressure increase and / or decrease of the pressure control valve.Likewise, an actuator module with a different operating principle (e.g., NC (normally closed) or NO (normally open)) or other magnetic and / or spring forces and / or force curves can be selected. Likewise, the pressure control valve (for different applications) can be adapted to different external mechanical, hydraulic, and / or electrical interface or installation space requirements.

[0031] In a preferred embodiment, the pressure control valve according to the invention comprises, as a further functional module, a main stage module which implements (exactly or at least) the functionality of the main stage of the pressure control valve and for this purpose contains at least one main stage valve. The main stage of the pressure control valve is also implemented accordingly as a functional module. The main stage module is firmly connected to the actuator module (or possibly also to the pilot stage module). This is preferably again done via a press connection and / or exactly one mechanical interface or exactly one type of joining. In the simplest case, the main stage module is firmly connected to the actuator module or pilot stage module exclusively via a press connection. For this purpose, the main stage module and actuator module or pilot stage module each have corresponding, preferably cylindrical press surfaces which can be radial, coaxial, collinear orare arranged concentrically to the common valve axis of the pressure control valve. Furthermore, the main stage module or its main stage valve preferably has a central or symmetry axis, which particularly preferably coincides with the central axis of the pressure control valve in the assembled pressure control valve. The main stage module or its main stage valve is accordingly arranged coaxially to the pilot stage module and / or actuator module. Advantageously, the main stage module or at least its main stage valve is also cylindrical or substantially cylindrical and / or rotationally symmetrical (optionally apart from radial fluid openings). Furthermore, what was said above with regard to the pilot stage module also applies mutatis mutandis to the main stage module. The main stage module advantageously comprises or consists of a main stage valve, which is designed as a passive seat valve or piston slide valve, and a main stage housing.Advantages arise in dynamic operation when the main stage valve is designed as a seat valve, as a seat valve has a faster response time. Compared to a piston spool valve, the seat valve reacts more quickly to sudden changes in flow rate because, unlike a piston spool valve, it does not require positive overlap to achieve low leakage. This allows pressure overshoots in the main stage valve, for example, to be reduced or eliminated during sudden changes in flow rate.

[0032] With this provision of a main stage module as an additional functional module, the pressure control valve accordingly comprises at least three functional modules. However, the pressure control valve preferably comprises (only) precisely these three functional modules (actuator module, pilot stage module, and main stage module) and is constructed from these three functional modules. In the simplest case, the pressure control valve consists precisely of an actuator module, a pilot stage module, and a main stage module. In the latter case, the pressure control valve is completely modular and can be assembled, for example, by providing (only) precisely fixed mechanical connections, preferably two press connections. Advantageously, all functional modules of the pressure control valve are firmly connected to one another (exclusively) via press connections.

[0033] In addition, further mechanical, hydraulic, and / or magnetic interactions can be provided between the functional modules. For example, a spring element of the main stage can be supported directly on the actuator module or the pilot stage module. Likewise, the above-described actuation of the pilot stage valve in the pilot stage module takes place via the actuator module or its actuating element. Furthermore, the main stage module, together with the pilot stage module and, if applicable, also the actuator module, forms the pilot chamber.

[0034] In a preferred embodiment, the actuator module itself is also modular in design or divided into sub-modules and comprises a coil module, a magnetic drive module, and a coil cover module, or consists (exclusively) of these three modules. To form the actuator module, the magnetic drive module is preferably firmly connected to the coil cover module, and the coil module is then firmly connected to the coil cover module, thereby particularly preferably closing the magnetic circuit. The magnetic drive module is particularly preferably arranged entirely in an interior space created by the coil module and coil cover module. The coil module and coil cover module together preferably create a housing for the actuator module, which particularly preferably has (only) a through-opening for the actuating element on the actuator axis and / or is otherwise completely closed, and for this purpose preferably has a completely closed outer skin.The coil module comprises at least one magnetic coil and electrical connections for energizing the magnetic coil, as well as preferably magnetically conductive material for (partially) forming the magnetic circuit on an end face (facing away from or at the rear of the pilot stage module or main stage module) and particularly preferably also on the radial outer side of the coil module or coil. The magnetic drive module comprises an actuating element mounted for linear movement (along the actuator axis of the actuator module or the central axis of the pressure control valve) (in the simplest case consisting only of a magnetic armature or optionally further comprising a non-magnetic plunger firmly connected thereto), as well as one or more magnetically conductive components fixed in the actuator module or coil module (when arranged as intended), at least one fixed pole core which magnetically attracts or repels the magnetic armature when the coil is energized.towards which the magnet armature moves when sufficient current is supplied. The pole core is usually arranged on the actuator axis and, depending on the design of the magnetic drive module, may serve as a stop for the magnet armature. The magnetic drive module preferably also has a pole tube, a spring element and / or other fixed magnetically conductive components to form the magnetic circuit of the actuator module. Depending on the design of the magnetic drive module, when the coil is energized, the magnet armature or the actuating element then moves to the rear or the opposite front end of the coil module or the magnet coil. In other words, in the first case, the actuating element moves into the actuator module when energized, resulting in NC functionality for the pilot stage; in the latter case, the actuating element extends out of the actuator module when energized, resulting in NO functionality for the pilot stage.The coil cover module also contains magnetically conductive material at least on the front end face (possibly also on the radial outer side) of the coil module or coil, thus closing the magnetic circuit around the magnetic coil. The coil cover module can also be referred to as a housing plate. The coil cover module preferably further comprises a through-hole for an actuating element (for example, the magnet armature or a plunger (fixedly) connected thereto). Furthermore, the through-hole preferably comprises the pressing surface of the actuator module or coil cover module for forming the press connection with the pilot stage module.

[0035] These three modules of the actuator module are preferably preassembled assemblies, with the coil cover module particularly preferably being formed in one piece and then correspondingly consisting entirely of magnetically conductive material. Furthermore, the coil module and the magnetic drive module are preferably each firmly connected to the coil cover module via (exactly) one press connection. These press connections are preferably created by corresponding cylindrical press surfaces, which are particularly preferably arranged coaxially to the central axis. This not only allows for simple assembly of the actuator module. The advantageous subdivision of the components of an actuator module into these three modules or sub-modules outlined above also avoids cross-module components, so that to create variants of the actuator module, one of its modules can be replaced with a variant of it without necessitating changes to the other modules.In particular, the component selection for the magnetic drive module described above allows for the provision of magnetic drive modules with opposing or different functionalities (NO or NC functionality) while leaving all interfaces (geometric, magnetic, etc.) to the other modules of the actuator module unchanged. The connection between the magnetic drive module and the coil cover module is preferably additionally welded to ensure strength and tightness under pressure.

[0036] In a preferred embodiment of the pressure control valve, the coil cover module is arranged centrally in the pressure control valve and / or preferably forms one or the only central component of the pressure control valve, to which all other functional modules and modules or sub-modules are particularly preferably firmly connected. Accordingly, the coil cover module is preferably firmly connected to the pilot stage module, the main stage module, the coil module and the magnetic drive module via one or exactly one press connection each. Particularly preferably, the press connection between the coil cover module and the pilot stage module forms the only fixed connection between the coil cover module and the pilot stage module. Particularly preferably, the press connection between the coil cover module and the main stage module forms the only fixed connection between the coil cover module and the main stage module.Particularly preferably, the press connection between the coil cover module and the coil module forms the only fixed connection between the coil cover module and the coil module. Particularly preferably, in addition to the press connection between the coil cover module and the magnetic drive module, a weld, in particular a laser weld, is additionally provided between the coil cover module and the magnetic drive module. Accordingly, to create the (exactly) four press connections to the pilot stage module, main stage module, coil module, or magnetic drive module, the coil cover module preferably has (exactly) four press surfaces, which are particularly preferably each cylindrical and / or arranged coaxially to the central axis. Furthermore, the pilot stage module, the main stage module, the coil module, and the magnetic drive module preferably have no fixed connection to one another, in particular no press connection, screw connection, and / or weld connection.This promotes the modularity of the pressure control valve and limits changes in the pressure control valve as a result of changes to one of the functional modules or modules or sub-modules that affect the respective attachment to the coil cover module, in the simplest case to a corresponding adaptation of the coil cover module.

[0037] The present invention further comprises a shock absorber with one, two, or more of the pressure control valves described above. In the simplest case, the shock absorber comprises a pressure cylinder in which an axially movable piston divides the volume of the pressure cylinder into two pressure chambers. In an advantageous embodiment, the shock absorber then comprises two of the pressure control valves described above, with a pressure control valve and, if appropriate, a check valve being provided for each of the two possible flow directions between the pressure chambers. In an alternative embodiment, the shock absorber comprises precisely one pressure control valve combined with a fluid rectification system. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The invention is described below with reference to the accompanying drawings. The drawings are merely schematic representations, and the invention is not limited to the specific embodiments shown. Figures 1A, B, C show various perspective sectional views of a pressure control valve with an NO magnetic drive module, Figure 2 shows a perspective sectional view of a pressure control valve with an NC magnetic drive module, Figures 3A, B, C show sectional views through a pilot stage module, Figures 4A, B show various pQ characteristic curves, Figure 5A shows a sectional view through a second embodiment of a pilot stage module, Figure 5B shows a perspective view of a failsafe component, Figure 6 shows a pQ characteristic curve of a pilot stage according to the second embodiment, and Figure 7 shows a schematic representation of a shock absorber with two pressure control valves. DETAILED DESCRIPTION

[0039] In Figure 1A A pressure control valve 1 is shown in a perspective sectional view. The pressure control valve consists of exactly three functional modules: an actuator module 2, a pilot stage module 3 and a main stage module 4. Figure 1B 1 shows a perspective exploded view of these three functional modules 2, 3, 4. The pilot stage module 3 has a radially outer, cylindrical pressing surface 31, which, with a corresponding pressing surface 211 in the actuator module 2 or its coil cover module 21, creates a press connection between the actuator module 2 and the pilot stage module 3. Likewise, the main stage module 4 also has, in the illustrated embodiment, a radially inner, cylindrical pressing surface 41, which, with a corresponding pressing surface 212 in the actuator module 2 or the coil cover module 21, creates a press connection between the main stage module 4 and the actuator module 2.

[0040] The main stage module shown has an axial connection for the fluid or hydraulic fluid to be controlled, radial outlet openings 42, and a main stage valve 43 with a valve body 431 that is axially movable along the central axis of the pressure control valve 1. In the illustrated embodiment, the main stage valve 43 is a piston slide valve. The valve body 431 is urged against a stop 433 by a spring element 432, thereby closing the main stage valve 43 in the depressurized state. The control edge of the valve body 431 is located on its outer diameter and interacts with the radial outlet openings 42.

[0041] In a variant not explicitly shown, the main stage valve 43 is a seat valve. Figure 1A and 1BThe stop 433 shown then forms, in the simplest case, a valve seat 433, so that the control edge of the valve body 431 is located on its axial side facing the valve seat 433 and this then interacts with the valve seat 433.

[0042] Furthermore, the valve body 431 of the main stage valve 43 (in both of the above-mentioned embodiments) comprises a throttle 434 in a manner known per se and thus creates the pilot chamber 5 in cooperation with the pilot stage module 3 and in this case the actuator module 2. As a result, the main stage valve 43 opens when a sufficiently low pressure prevails in the pilot chamber 5 or when the pressure drop at the throttle of the valve body 431 generates a force that overcomes the spring force of the spring element 432.

[0043] In Figure 1CThe modular actuator module 2 is also shown in an exploded view with respect to its assemblies or modules: coil cover module 21, magnetic drive module 22, and coil module 23. The coil module 23 comprises a magnetic coil 231, magnetically conductive material 232 for creating (part of) the magnetic circuit, and an electrical connection 233 for supplying the magnetic coil 231. The magnetic drive module 22 has an actuating element in the form of a magnetic armature 221, which is linearly movable along an actuator axis, which also coincides with the central axis 11 of the pressure control valve 1 in the figures, and in this case directly actuates a valve body 33 of the pilot stage valve 32 of the pilot stage module 3. The coil cover module 21 is constructed in one piece from magnetically conductive material, closes the magnetic circuit, and, together with the coil module, creates a housing for the actuator module 2.In the illustrated embodiment, the coil cover module 21 and the coil module 23 are firmly connected to one another exclusively via a single press connection. Furthermore, the coil cover module 21 and the magnetic drive module 22 are firmly connected to one another via a press connection and additionally via a weld. The modules of the actuator module 2 have corresponding press surfaces for this purpose. In contrast, the magnetic drive module 22 and the coil module 23 are not firmly connected to one another.

[0044] The Figure 1A , B and C has a pole core 223, which is arranged at an end of the magnetic drive module directed towards the pilot stage module 3. When the magnetic coil 231 is energized, the magnetic armature 221 moves in the direction of the pole core 223 and thus in the direction of the pilot stage module 3. Accordingly, the pilot stage valve 32 is closed when energized, so that the Figures 1A to 1CThe magnetic drive module 22 shown creates an NO valve.

[0045] In Figure 2 is a variant of the pressure control valve 1 from the Figures 1A to 1C , which differs only in the design of the magnetic drive module 22. Here, the pole core 223 is arranged at the end of the magnetic drive module 22 facing away from the pilot stage module, so that the magnet armature 221 moves away from the pilot stage module 3 when energized. Furthermore, a spring element 224 is provided, which urges the magnet armature 221 away from the pole core 223 and towards the pole stage module 3 when de-energized, so that the pilot stage module 32 is closed when de-energized. Figure 2 The magnetic drive module 22 shown thus creates an NC valve.

[0046] In Figure 3AA section through a pilot stage module 3 is shown. This comprises a module body 34 and a valve body 33, which in this case is designed as a ball valve body. The module body 34 comprises on the inside a valve seat 341, which in this case is designed as a conical seat, as well as downstream therefrom, that is to say in Figure 3A at the top, a guide section 342 with a cylindrical, internal guide for the ball valve body 33 when it lifts off the valve seat 341. Furthermore, the module body 34 comprises radial outflow openings 343 for the fluid when the pilot stage valve 32 is open, which in the illustrated embodiment are arranged axially between the valve seat 341 and the guide section 342. The module body further comprises the pressing surface 31 already described above on its radial outer side.

[0047] In Figure 3Athe pilot stage module 3 or its pilot stage valve 32 is shown in the closed state; the ball valve body 33 closes the cone valve seat 341. In Figure 3B the pilot stage valve is shown in the open state; the ball valve body 33 lifts off the cone valve seat 341 and the fluid flows from the pilot chamber 5 through the interior of the module body 34 past the valve seat 341 and the valve body 33 and leaves the pilot stage module 3 via the radial outflow openings 343.

[0048] Furthermore, the module body 34 comprises a recess 344 upstream of the valve seat 341 for receiving a fluid component 35. This is designed as a throttle 35, as shown in Figure 3CSuch a throttle 35 allows, for example, the gradient in a pQ diagram, i.e., the increase in fluid flow relative to the increase in applied pressure, to be adjusted or varied. Furthermore, the damping of the main stage and thus the dynamic behavior of the valve can be influenced by means of the orifice or throttle 35.

[0049] In Figure 4A and 4BVarious pQ diagrams of the pressure control valve 1 are shown. Generally, when the pressure increases from zero, no fluid initially flows through the pressure control valve 1, since the main stage valve 42 and the pilot stage valve 32 are closed. When the so-called opening pressure is reached, the pilot stage valve 32 opens, causing a pressure drop in the pilot chamber 5, which then also opens the main stage valve 42. After the opening pressure is reached, the fluid flow through the pressure control valve 1 increases with a slight gradient and, in this case, approximately linearly, as the pressure continues to increase.

[0050] In Figure 4ADifferent characteristic curves for different seat diameters of the conical valve seat 341 are shown. Generally, for a given pressure applied to the pressure control valve 1, a smaller seat diameter exerts a lower hydraulic force on the valve body 33 than a larger seat diameter. Accordingly, with a small seat diameter, the pilot stage valve only opens at a relatively high opening pressure. Figure 4A Characteristic curve 4A1, which has the highest opening pressure, corresponds to the smallest seat diameter of the cone valve seat 341, characteristic curve 4A2 with a medium opening pressure corresponds to a medium seat diameter, and characteristic curve 4A3 with a low opening pressure corresponds to the largest seat diameter. The remaining parameters, such as the current supply to pressure valve 1, were kept constant and, in this case, set to the maximum current.

[0051] In Figure 4BpQ characteristic curves are again shown, here for the case of different sizes of the air gap 223 between the magnet armature 221 and the pole core 222. In the present case, this is achieved by an axial displacement of the pilot stage module 3 in the actuator module 2 or its coil cover module 21, with the pilot stage module 3 and the actuator module 2 being connected via a press connection. In the present case, it is assumed that this is an NO valve. The upper characteristic curve 4B1 in the diagram with the greatest opening pressure is achieved with a small air gap, i.e. when the pilot stage module 3 is inserted less deeply into the actuator module 2 and, accordingly, the magnet armature 221 only strikes the valve body 33 of the pilot stage valve 32 when the air gap 223 to the pole core 222 is relatively small.In contrast, the lower characteristic curve 4B3 in the diagram corresponds to the case where the magnet armature 221 already strikes the valve body 33 of the pilot stage valve 32 at a relatively large air gap 223, which can be achieved by inserting the pilot stage module 3 deeper into the actuator module 2. The middle characteristic curve 4B2 then corresponds to an air gap 223 of medium size.

[0052] In Figure 5A a section through a second embodiment of a pilot stage module 3 is shown, which has a throttle 35. In addition to the throttle 35 shown, for example, in Figure 3C The configuration shown includes the Figure 5The second exemplary embodiment shown includes a fail-safe valve seat 36 as the second valve seat, which is opposite the cone valve seat 341 as the first valve seat and is itself also designed as a cone seat. Furthermore, the second exemplary embodiment of the pilot stage module 3 includes a spring element 37, which urges the ball valve body 33 into the fail-safe valve seat 36 and, when de-energized, also holds it in the fail-safe valve seat 36. In the exemplary embodiment shown, the fail-safe valve seat 36 is provided via an additional component, the so-called fail-safe component 38.

[0053] In Figure 5BA perspective interior view of the failsafe component 38 is shown. In this second exemplary embodiment, the guide section 342 for the ball valve body 33 is not created by the module body 34, but by the failsafe component 38, wherein the failsafe component 38 is arranged as a cap axially on the downstream side of the cone valve seat 341 on the module body 34. Likewise, there are no radial outflow openings in the pilot stage module 3 or the module body 34; rather, the axial opening of the failsafe valve seat 36 is the only fluid passage opening in the pilot stage module 3 according to the second exemplary embodiment.

[0054] If the ball valve body 33 is located in the failsafe valve seat 36, it is not completely closed. This is ensured in the present case by lateral bypass openings 381 in the guide section 342 of the failsafe valve seat 36 and / or by a non-circular contour of the failsafe valve seat 36 or its fluid passage opening. In the illustrated embodiment, the failsafe valve seat is a polygon in the shape of a regular octagon. However, other, preferably regular, polygons can also be used.

[0055] In the de-energized case, when the solenoid armature 221 exerts no force on the pilot stage valve 32 (NO valve or actuator module whose solenoid armature extends when energized), the ball valve body 33 is held in the downstream fail-safe valve seat 36 by the spring element. This does not completely close the fluid path through the pilot stage valve 32, but rather ensures a certain (average, non-zero, non-maximum) free fluid cross-section through the bypass openings 381 or, for example, through the polygonal shape of the fail-safe valve seat 36 in the de-energized case. In this operating state, the pilot valve then acts like an additional, constant throttle in the pilot stage valve 32. Since the fail-safe valve seat 36, with its throttling effect, is located downstream of the pilot chamber 5, in which the pressure for controlling the main valve is built up, the fluid in the pilot chamber 5 is additionally backed up.Consequently, a higher pressure must be applied to the main stage valve to generate the pressure drop across the valve body 431 of the main stage valve 43 or its throttle, which is required to open the main stage valve 43. Therefore, the opening pressure of a fail-safe characteristic curve 6A2 in the pQ diagram (see . Figure 6 ) higher than that of the characteristic curve for the so-called minimum current 6A3, at which the pilot stage valve 32 is maximally open or has the largest fluid passage cross-section.

[0056] During the so-called minimum current supply to the coil, the ball valve body 32 is lifted from the fail-safe valve seat 36 by the solenoid armature 221, generally the actuating element of the actuator module 2, against the spring force of the spring element 37 and moved into a middle position between the fail-safe valve seat 36 and the cone valve seat 341. Thus, at the minimum current supply, a pQ characteristic curve is realized which (analogous to an NO valve) has only a low opening pressure and is approximately linear with a slight gradient above the opening pressure. The opening pressure is not zero in this case either, since a minimum pressure must first be built up at the main stage in order to generate a sufficient pressure drop across the throttle of the valve body 43 of the main stage valve 42 to overcome the spring force of the spring element 432 of the main stage valve 43.

[0057] At maximum current, the ball valve body 33 is pressed onto the cone valve seat 341 of the pilot stage valve 32 in the pressureless case, so that the pilot stage valve 32 only opens after overcoming the magnetic force, i.e. only at a relatively high opening pressure (characteristic curve 6A1 in Figure 6 ). As the pressure continues to increase, the fluid flow increases in the same way as at the minimum current.

[0058] In contrast, in the de-energized case, when the valve body 32 is seated in the failsafe valve seat 36, a greater increase in pressure at the main stage is required to generate the necessary pressure differential. Consequently, the volume flow increases significantly more slowly with increasing pressure at the main stage in the de-energized case (failsafe case) than with minimum or maximum current.

[0059] In Figure 7A shock absorber 6 with two pressure control valves 1 is shown schematically. The shock absorber 6 comprises a pressure cylinder 61 in which an axially movable piston 62 divides the volume of the pressure cylinder into two pressure chambers, which are connected for each flow direction via a pressure control valve 1 (and a check valve). Figure 7 Instead of the two pressure control valves 1 shown, a single pressure control valve 1 with a fluid rectification (not shown) can also be used. LIST OF REFERENCE SYMBOLS

[0060] 1Pressure control valve 11Central axis 2 Actuator module 21 Coil cover module 211 Pressing surface 212 Pressing surface 22 Magnetic drive module 221 Magnetic armature, actuating element 222 Pole core 223 Air gap 224 Spring element 23 Coil module 231 Magnetic coil 232 Magnetically conductive material 233 Electrical connection 3 Pilot stage module 31 Press surface 32 Pilot stage valve 33 Valve body, ball valve body 34 Module body 341 Valve seat, cone valve seat 342 Guide section 343 Radial outlet openings 344 Recess for 35 35 Throttle, orifice, fluid component 36 Fail-safe valve seat 37 Spring element, coil spring 38 Fail-safe component 381 Bypass openings 4 Main stage module 41 Press surface 42 Radial drain openings 43 Main stage valve 431 Valve body 432 Spring element, coil spring 433 Stop / valve seat 434 Throttle 5Pilot room 6Shock absorber 61Pressure cylinder 62Piston

Claims

1. A pressure regulation valve (1) comprising a pilot stage valve (32) with a ball valve body (33) characterized by a conical seat (341), wherein - the pilot stage valve (32) has a single-piece module body (34) which has the conical seat (341) and the guide section (342) for the ball valve body (33), and / or - the pilot stage valve (32) has a or the already before the last "and" mentioned guide section (342) for the ball valve body (33) that has a cylindrical inner wall having an inner diameter that corresponds to the diameter of the ball valve body plus play.

2. The pressure regulation valve (1) according to claim 1, characterized in that - the pilot stage valve (32) has a receiving section (344) for receiving a fluid component, in particular a throttle, which preferably has a thread.

3. The pressure regulation valve (1) according to any of the preceding claims, characterized in that - the pilot stage valve (32) has a failsafe valve seat (36), preferably at the end of the guide section (342) located opposite the conical seat (341), and preferably a spring member (37), which biases the ball valve body (33) into the failsafe valve seat.

4. The pressure regulation valve (1) according to any of the preceding claims, comprising a multiplicity of function modules, preferably pre-mounted function modules, comprising an actuator module (2) and a pilot stage module (3), which comprises the pilot stage valve (32) or consists thereof, wherein preferably the pilot stage module (3) and the actuator module (2) are firmly interconnected via a press connection, in particular exclusively via a press connection, and preferably have a central axis (11).

5. The pressure regulation valve (1) according to claim 4, further comprising a main stage module (4) as a further function module, which is preferably firmly connected to the actuator module (2) or the pilot stage module (3) via a press connection and / or which has a main stage valve (43) which is formed as a piston slide valve or as a seat valve.

6. The pressure regulation valve (1) according to any of claims 4 to 5, characterized in that the pressure regulation valve consists of or is constructed exclusively from function modules and / or at least or exactly of / from the actuator module (2), the pilot stage module (3) and the main stage module (4).

7. The pressure regulation valve (1) according to any of claims 4 to 6, characterized in that the actuator module (2) has an actuator with an actuator axis, wherein preferably the actuator is formed as a linear actuator and / or the actuator module has a cylindrical press area (211, 212), which is arranged particularly preferably coaxially to the actuator axis.

8. The pressure regulation valve (1) according to any of claims 4 to 7, characterized in that the pilot stage module (3) - has a pilot stage valve (32) which can be operated preferably along a valve axis and / or - has a cylindrical press area (31) which is preferably arranged coaxially to the valve axis.

9. The pressure regulation valve (1) according to claims 7 and 8, characterized in that the actuator axis and the valve axis of the pilot stage valve (32) form a common central axis (11) of the pressure regulation valve.

10. The pressure regulation valve (1) according to any of claims 4 to 9, characterized in that an operation member (221) of the actuator module (2) abuts on a valve body (33) of the pilot stage module (3) for operating the pilot stage valve (32).

11. The pressure regulation valve (1) according to any of claims 5 to 10, characterized in that the press connection between the main stage module (4) and the actuator module (2) or the pilot stage module (3) is created by corresponding cylindrical press areas (41, 212), which are preferably arranged coaxially to the central axis (11).

12. The pressure regulation valve (1) according to any of claims 4 to 11, characterized in that the actuator module (2) comprises a coil module (23), a magnetic drive module (22) and a coil lid module (21), wherein preferably the coil module and the magnetic drive module are firmly connected to the coil lid module via a press connection in each case, wherein each of the press connections is created preferably by respectively two corresponding cylindrical press areas, which are arranged particularly preferably coaxially to the central axis (11), and / or wherein preferably no firm connection, particularly preferably no press connection, is provided between the coil module and the magnetic drive module.

13. The pressure regulation valve (1) according to claim 12, characterized in that the coil lid module (21) is arranged centrally in the pressure regulation valve and / or the coil lid module (21) is firmly connected to the pilot stage module (3), the main stage module (4), the coil module (23) and the magnetic drive module (22) via respectively one press connection and preferably the pilot stage module, the main stage module, the coil module and the magnetic drive module do not have a firm connection, preferably no press connection, among each other.

14. The pressure regulation valve (1) according to claim 12 or 13, characterized in that the magnetic drive module (22) has a movably borne operation member (221) or a movably borne magnetic armature and preferably a pole core (222).

15. A shock absorber (6) comprising one, two or several pressure regulation valves (1) according to any of the preceding claims.