High-Flow Valve Diaphragm Balancing for Lower Solenoid Power
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Solution Overview
Problem
High flow cartridge valves require large solenoid magnetic forces, resulting in extensive power consumption, heavy, and expensive valve assemblies, necessitating a solution for a more efficient and cost-effective design.
Innovation Solution
The high flow valve design incorporates a diaphragm with balanced forces to reduce the magnetic force needed for valve operation, using a solenoid coil with a reduced power requirement, and eliminates the need for an adjustable pole piece by over-pressing the valve seal against the supply seat to set the initial air gap, allowing for a smaller, lighter, and less expensive assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large solenoid magnetic force is used to initiate valve position shift, then the valve can achieve high flow rate, but the power consumption increases and the valve assembly becomes heavy and expensive
Solution Approach 1:
The patent applies the counterweight principle by introducing a balanced force mechanism where the diaphragm creates a force that opposes and balances the solenoid magnetic force. This balancing reduces the net force required from the solenoid, thereby reducing power consumption while maintaining the ability to achieve high flow rates when the valve shifts position.
Solution Approach 2:
The patent changes the force balance parameters by introducing a diaphragm that creates a counterbalancing force. This parameter change allows the solenoid to operate with reduced magnetic force requirements, directly addressing the power consumption issue while preserving flow rate capability through the modified force equilibrium.
2Productivity
If a large solenoid magnetic force is used to initiate valve position shift, then the valve can achieve high flow rate, but the valve assembly becomes larger and heavier
Solution Approach 1:
The balanced force mechanism using the diaphragm counteracts the need for large solenoid forces, allowing for a smaller, lighter valve assembly design that can still achieve high flow rates when actuated. The counterbalancing force enables reduced solenoid sizing.
Solution Approach 2:
The patent replaces part of the mechanical force requirement with a pneumatic/hydraulic balancing mechanism (diaphragm force), substituting pure mechanical solenoid force with a combined force system that reduces overall component size and weight.
3Force
If an adjustable pole piece is used to set the air gap, then the initial solenoid magnetic force can be optimized, but the device complexity increases
Solution Approach 1:
The patent removes the adjustable pole piece component entirely, extracting this source of complexity from the system. The air gap is set through alternative means (such as fixed positioning or assembly tolerances) while the force optimization is achieved through the diaphragm balancing mechanism rather than pole piece adjustment.
Solution Approach 2:
The valve assembly is designed to self-set the appropriate air gap through its assembly structure or tolerances, eliminating the need for manual adjustment mechanisms. The force balance is achieved through the self-actuating diaphragm mechanism rather than requiring adjustable components.
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 design achieves a high flow rate with reduced power consumption and costs, minimizing mechanical shifting noise and allowing for a larger valve stroke, while maintaining effective sealing and reduced mechanical complexity.
Implementation Method 1
Many cartridge valves use a solenoid magnetic force to initiate a shift in valve position
Implementation Method 2
The high flow valve design incorporates a diaphragm with balanced forces to reduce the magnetic force needed for valve operation
Implementation Method 3
eliminates the need for an adjustable pole piece by over-pressing the valve seal against the supply seat to set the initial air gap
Data Source
AI summary
A system and method for a high flow valve includes a seal rod, an armature configured to be connected to and move the seal rod, a valve seal configured to be connected to the seal rod, an exhaust seal seat and a diaphragm. The valve seal is configured to be positioned on the exhaust seal seat and exert an exhaust seal pressure force. The diaphragm is configured to exert a diaphragm force opposite the exhaust seal pressure force to balance the exhaust seal pressure force.