Additive Valve Piston Passage Design for Lower Hydraulic Pressure Loss

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Solution Overview

Problem

Conventional valve pistons for hydraulic systems require complex and costly manufacturing processes, leading to high pressure loss and inefficient fluid flow due to dead zones and turbulence, which necessitate additional pump output and reduce energy efficiency.

Innovation Solution

A valve piston with an additively manufactured internal passage that is flow-optimized by being radially separated from the central axis, featuring a convex shape and variable cross-sections to minimize pressure loss, and is produced using power bed-based selective laser melting with steel materials, eliminating the need for joints and reducing design limitations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional multi-component valve pistons are manufactured using machining and joining processes, then structural integrity can be achieved, but manufacturing complexity and production time increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (pin, sleeve, control flanges) into a single integrated valve piston body manufactured by additive manufacturing. This eliminates the need for joining processes while maintaining structural integrity, directly resolving the contradiction between strength and manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process enables the valve piston to serve multiple functions in a single component: structural support, fluid guidance through internal passages, and control surface functionality. This multi-functionality reduces the number of separate components needed while maintaining required performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If conventional joining processes are used to assemble valve piston components, then assembly can be completed, but testing requirements increase to verify joint strength and leak-tightness

Engineering Contradiction:

Improveassembly capabilityVSAvoidjoint reliability verification

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

By combining all valve piston components into a single additively manufactured unit, the patent eliminates joining interfaces that would require testing. The single-component design maintains ease of manufacture through additive processes while removing reliability concerns associated with joint verification.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If internal ducts are formed using conventional machining processes, then manufacturing can be completed, but pressure loss increases due to suboptimal flow paths

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidpressure loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent changes the manufacturing parameter from conventional machining to additive manufacturing, enabling optimized internal passage geometries with smooth transitions and minimal dead zones. This parameter change reduces pressure loss while maintaining manufacturability through modern additive processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The additively manufactured internal passages feature curved, optimized flow paths instead of sharp angles or abrupt transitions typical of machined ducts. This curvature optimization promotes laminar flow and reduces turbulence, directly decreasing pressure loss.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Power

If pump output is increased to compensate for pressure loss, then hydraulic system performance can be maintained, but energy efficiency decreases

Engineering Contradiction:

Improvehydraulic system performanceVSAvoidenergy efficiency

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

By changing the internal passage geometry parameters through additive manufacturing optimization, the patent reduces pressure loss in the hydraulic fluid flow. This allows the system to maintain required power output with lower pump energy input, improving energy efficiency.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution significantly reduces pressure loss and improves hydraulic fluid flow by optimizing the passage design, enhancing energy efficiency and simplifying the production process while maintaining structural integrity.

Implementation Method 1

the passage is delimited towards the central axis, that is to say it does not extend as a simple, central passage in the valve piston but is rather separated by a radial distance from the central axis

Methodology Applied

Scientific EffectFluid flow optimization through geometric design:

Implementation Method 2

produced using power bed-based selective laser melting with steel materials

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Data Source

PatentUS11493144B2Valve piston and valve comprising the valve piston

Publication Date: 2022.11.08 ROBERT BOSCH GMBH

AI summary

A valve piston has a central axis along which mutually spaced control geometries are provided, which are bypassed by a passage that extends through the valve piston. The valve piston is, at least in portions, manufactured additively. A valve is includes a valve housing and a housing recess, in which the valve piston is received so that it is adjustable relative to the valve housing.