Additive Hydraulic Valve Geometry for Tailored Flow Control
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Solution Overview
Problem
Current hydraulic valve assemblies in heavy machinery, such as those used in earth moving, construction, and mining industries, have limited complexity in their component geometries due to conventional machining, restricting the tailoring of performance characteristics like stability and fluid flow metering.
Innovation Solution
The use of additive manufacturing to create valve components with intricate features, such as lattice structures and asymmetrical configurations, which define flow apertures and orifices, allowing for more precise control of hydraulic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional machining is used to manufacture valve components, then manufacturing simplicity is maintained, but geometric complexity and performance tailoring are limited
Solution Approach 1:
The patent changes the manufacturing method from conventional machining to additive manufacturing, enabling complex geometries (lattice structures, asymmetrical configurations, varying flow apertures) that cannot be achieved through traditional subtractive processes. This parameter change in manufacturing technology directly resolves the contradiction by allowing high geometric complexity while maintaining manufacturing efficiency.
2Manufacturing precision
If conventional machining is used, then manufacturing process simplicity is maintained, but hydraulic performance tailoring is restricted
Solution Approach 1:
The patent applies local quality by creating spatially varying geometries within valve components, such as lattice structures with different densities in different regions, asymmetrical flow apertures, and localized feature variations. These local geometric variations enable precise control of hydraulic performance characteristics like flow metering and stability without requiring complex assembly of multiple parts.
Solution Approach 2:
The patent transitions from two-dimensional surface features to three-dimensional volumetric structures by incorporating lattice structures and asymmetrical configurations that extend throughout the component volume. This dimensional enhancement allows for sophisticated hydraulic performance tailoring that cannot be achieved with conventional surface-level machining operations.
3Reliability
If standard valve components are used, then device simplicity is maintained, but shock load transmission is reduced only minimally
Solution Approach 1:
The patent incorporates lattice structures and asymmetrical configurations that act as shock-absorbing features built into the valve components before operation. These pre-designed geometric features dissipate shock loads through controlled deformation and energy absorption mechanisms, reducing transmission of shock loads to other system components while maintaining overall valve stability.
Data Source
AI summary
A method of manufacturing a hydraulic valve component using additive manufacturing includes laying successive layers to form a flow aperture for a hydraulic valve component, and creating a lattice or mesh structure that at least partially defines the flow aperture of the hydraulic valve component, or a feature that forms an undercut along a direction that is parallel to a flow direction of the flow aperture, or a flow aperture having a size varying along a circumferential direction of the valve component.