Electrohydraulic Pilot Control with Encapsulated Magnets
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Solution Overview
Problem
The existing electrohydraulic pilot control systems with multiple pressure control valves face high mounting costs and testing complexities due to the need for precise alignment and orientation of valve components, which can lead to undesirable transverse forces and hysteresis.
Innovation Solution
The solution involves encapsulating proportional magnets in plastic and fastening them to a control block using a flange, with precise orientation ensured by positioning means, and integrating the hydraulically acting valve components within the block, allowing for joint testing and reduced hysteresis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pressure control valves are fitted at different points on the appliance using traditional mounting methods, then the valves can be installed, but mounting costs and testing complexities increase significantly
Solution Approach 1:
The patent combines multiple pressure control valves into a single integrated control block assembly. The valves are pre-mounted and pre-aligned within the control block, which is then installed as one unit on the appliance. This merging of multiple components into a single assembly reduces mounting operations, lowers labor costs, and simplifies testing procedures.
Solution Approach 2:
The control valves are pre-positioned and pre-aligned within the control block during manufacturing, before installation on the appliance. The positioning means (projections and cavities) are built into the control block structure in advance, ensuring precise orientation without requiring complex alignment procedures during field installation.
2Manufacturing precision
If traditional mounting methods are used without precise positioning means, then assembly is simpler, but transverse forces and hysteresis increase due to misalignment
Solution Approach 1:
The patent introduces positioning means consisting of projections on valve sleeves and matching cavities in the control block as an intermediary mechanism. These positioning features act as mediators that automatically ensure precise alignment between the valve components and the control block during assembly, eliminating misalignment without requiring complex external alignment procedures.
Solution Approach 2:
The positioning means use asymmetric geometric features (specific projections and matching cavities) rather than symmetric arrangements. This asymmetric design ensures a unique, precise orientation of the valve components relative to the control block, preventing unwanted rotation or misalignment while maintaining structural simplicity.
3Ease of manufacture
If magnets are not jointly encapsulated and mounted, then individual component manufacturing is easier, but overall system costs and testing requirements increase
Solution Approach 1:
The patent encapsulates multiple magnet assemblies together with the control valves within a single control block housing. This joint encapsulation creates an integrated assembly that is manufactured and tested as one unit, reducing overall system costs by eliminating separate testing requirements for each magnet and reducing assembly operations during installation.
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 approach significantly reduces costs and testing complexities while ensuring accurate alignment, minimizing hysteresis and allowing for comprehensive system testing without pre-mounting on the appliance, enabling cost-effective and precise production of adjustment systems for large proportional directional valves.
Implementation Method 1
the two magnets are equipped with in each case one bow-shaped metal sheet which guides the magnetic flux
Implementation Method 2
the two proportional magnets are joined by being encapsulated with plastic to form an assembly... designed this model such that the pressure control valves have a good degree of proportionality between the coil current and the control pressure
Data Source
AI summary
Electrohydraulic pilot control means (1) for a hydraulic device which can be a proportional directional valve, an adjusting pump or an adjusting motor, which pilot control means contains two proportionally acting pressure control valves (3) and is provided with a control block (2) which accommodates the hydraulic valve parts (4) in holes and to which the associated proportional magnets are flange-connected, wherein the proportional magnets have a common electrical plug connection (5) and wherein the two proportional magnets (3) are joined to form an assembly by being encapsulated with plastic, the said assembly being fastened to the control block (2) and, in this case, being precisely oriented relative to the valve components (4), which are accommodated in the control block, by means of positioning aids which act perpendicular to the movement direction of armatures.