Externally Damped EM Valve Assemblies for High-Vibration Reliability
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Solution Overview
Problem
Electromechanical valve assemblies in heavy-duty work vehicles face failure due to high-frequency vibrations, leading to issues like solder joint failure and connector fretting in harsh environments, which existing technologies have not adequately addressed.
Innovation Solution
The implementation of externally-mounted constrained layer dampers, comprising mass elements and viscoelastic layers, which are strategically positioned to attenuate vibrations before they reach the electronic components, thereby reducing the transmission of vibrational energy and minimizing failure modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromechanical valve assemblies are deployed in high vibratory environments, then they can perform critical functions for engine performance and emissions management, but they suffer from solder joint failure and connector fretting due to high-frequency vibrations
Solution Approach 1:
A constrained layer damper is introduced as an intermediary component between the housing and electronic components. The damper includes a viscoelastic layer sandwiched between two rigid layers, which absorbs and dissipates high-frequency vibrational energy, protecting solder joints and connectors from vibration-induced failure while allowing the valve assembly to function in harsh environments
Solution Approach 2:
The physical state of the damping material is utilized - the viscoelastic layer changes its stiffness characteristics based on frequency and temperature, providing optimal damping across the operating range. The material transitions between more rigid and more compliant states to effectively attenuate high-frequency vibrations without compromising structural integrity
2Reliability
If conventional EM valve assemblies are used without additional damping components, then the device complexity remains low, but the reliability deteriorates due to vibration-induced failures
Solution Approach 1:
The constrained layer damper is designed as a nested structure where the viscoelastic layer is sandwiched between two rigid layers. This compact nested configuration allows the damping function to be integrated into the existing housing structure without significantly increasing overall device complexity or volume
Solution Approach 2:
The damper utilizes composite construction with multiple material layers - rigid outer layers providing structural support and a viscoelastic inner layer providing damping. This composite approach achieves effective vibration attenuation while maintaining a compact design that integrates well with existing valve assembly structures
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 effectively reduces the amplitude of vibrations transmitted to electronic components, enhancing the reliability and longevity of EM valve assemblies by converting vibrational energy to heat, thus preventing failure modes associated with high-frequency vibrations.
Implementation Method 1
a first viscoelastic layer constrained between the first mass element and the exterior surface of the housing. The first viscoelastic layer deflects in shear as the first mass element moves relative to the housing to attenuate vibrations transmitted through the housing by conversion of vibrational energy to heat
Implementation Method 2
The constrained layer damper is tuned such that the first viscoelastic layer deflects in shear as the first mass element moves relative to the housing to attenuate vibrations transmitted through the housing by conversion of vibrational energy to heat
Data Source
AI summary
Externally-damped electromechanical valve assemblies well-suited for deployment within high vibratory operating environments, such as those associated with work vehicle engines, are provided. In embodiments, the valve assembly includes a housing through which a flow passage extends, a valve element positioned in the flow passage, a valve actuator, and control electronics electrically coupled to the valve actuator. The valve assembly may also contain a constrained layer damper including a first mass element and a first viscoelastic layer. The first mass element is mounted in suspension to the housing exterior for movement relative thereto when the first mass element is excited by vibrations transmitted through the housing. Constrained between the first mass element and the housing exterior, the first viscoelastic layer deflects in shear as the first mass element moves relative to the housing to attenuate the vibrations transmitted through the housing by conversion of vibrational energy to heat.