Axial Valve Merging Pilot and Main Elements
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Solution Overview
Problem
Existing axial valves with piloted control systems are complex, bulky, and costly due to their construction geometry and material requirements, making direct control of high-pressure fluid applications difficult and unreliable, and they often suffer from high power demands and vibration issues.
Innovation Solution
The axial valve is constructed using deep drawn sheet metal parts, allowing for a compact and cost-efficient design where the pilot valve element is slideably received inside the armature, which moves in unison with the main closing element, and a magnetic pilot valve is integrated within the housing to reduce volume and prevent moisture ingress, enabling efficient fluid flow and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piloted control system is used for high pressure fluid applications, then the valve can operate reliably at high pressures, but the construction becomes complicated and bulky
Solution Approach 1:
The pilot valve is integrated directly into the main valve body, with the pilot valve element arranged displaceable inside the armature which is fixed relative to the main closing element. This merging of pilot valve and main valve into a single integrated structure eliminates the need for separate pilot valve housing and attachment mechanisms, thereby reducing construction complexity while maintaining the reliable piloted control function for high pressure applications.
Solution Approach 2:
The pilot valve element is nested inside the armature, which itself is integrated with the main closing element. This nested arrangement allows the pilot valve components to be contained within the main valve structure, reducing overall valve volume and simplifying the external construction geometry while preserving the internal piloted control mechanism.
2Reliability
If a piloted control system is used for high pressure fluid applications, then the valve can operate reliably at high pressures, but the valve becomes bulky requiring more space
Solution Approach 1:
The pilot valve and main valve are merged into a single integrated structure where the pilot valve element is disposed inside the armature which is fixed to the main closing element. This integration eliminates the need for separate pilot valve housing and mounting space, significantly reducing the overall valve volume while maintaining reliable piloted control for high pressure operations.
Solution Approach 2:
The pilot valve element is nested within the armature structure, which is itself integrated with the main closing element. This nested configuration allows the pilot valve components to occupy internal space within the main valve body rather than requiring external attachment, thereby minimizing the total valve volume while preserving the functional integrity of the piloted control system.
3Device complexity
If direct control of main valve is used, then the construction is simpler, but high pressure forces require high power demand
Solution Approach 1:
The pilot valve element acts as an intermediary control mechanism that indirectly actuates the main closing element. By using fluid pressure differential created by the pilot valve to move the main closing element, the system avoids the need to directly overcome high pressure forces with mechanical actuators, thereby reducing power demand while maintaining construction simplicity.
Solution Approach 2:
The direct mechanical actuation system is replaced with a fluid pressure-based pilot control system. The pilot valve element uses fluid pressure differential to actuate the main closing element, substituting high-power mechanical direct actuation with a lower-power fluid pressure control mechanism, thereby reducing overall power demand while keeping the construction relatively simple.
4Reliability
If traditional piloted valve construction is used, then the valve can control high pressure fluid, but it requires a lot of material increasing costs
Solution Approach 1:
The pilot valve and main valve are merged into a single integrated structure with common housing and shared components. The pilot valve element is disposed inside the armature which is integrated with the main closing element, eliminating the need for separate pilot valve housing, mounting brackets, and additional fastening materials, thereby reducing material quantity and manufacturing costs while maintaining high pressure fluid control capability.
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
This solution results in a simpler, more compact, and cost-effective axial valve with minimized vibrations and transversal forces, achieving reliable operation and increased fluid flow capacity while reducing the risk of valve failure.
Implementation Method 1
a magnetic pilot valve is integrated within the housing
Data Source
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AI summary
The invention relates to an axial valve (1, 41, 59, 74) comprising a housing (2), an inlet (3), an outlet (4), a main valve (9, 75) and a pilot valve (18, 42, 61, 76). The opening and closing of the main valve (9, 75) is controlled by actuating the pilot valve (18, 42, 61, 76). The pilot valve (18, 42, 61, 76), comprises a pilot valve element (19, 46, 66, 77) and an armature (24, 83). The main valve (9, 75) comprises a main closing element (10, 52, 64). The object of the invention is to provide an axial valve with a cheaper and less complicated construction. To this end, the pilot valve element (19, 46, 66, 77) is arranged displaceable inside the armature (24, 83) and the armature's relative position to the main closing element (10, 52, 64) is fixed.