Integral Flapper-Nozzle Servo Valve for Low-Leakage Assembly
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Solution Overview
Problem
Conventional flapper-type servo valves are complex, bulky, and require precise manufacturing and calibration, with multiple potential failure points and leakage issues, making them costly and time-consuming to produce and maintain, while also being heavy and difficult to manufacture and assemble.
Innovation Solution
An integral flapper and nozzle structure formed from a single sheet of metal, where the flapper, nozzles, and orifices are cut using precise techniques like laser cutting, creating a compact, single-component package that simplifies assembly and reduces the need for additional sealing, allowing for precise calibration and easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional flapper-type servo valve systems are used, then fluid flow control functionality is achieved, but the system becomes complex, bulky, and requires precise manufacturing and calibration of multiple separate parts
Solution Approach 1:
The patent combines the flapper and nozzle into a single integrated component made from one sheet of metal. The flapper is formed by cutting and folding the sheet, while the nozzles are formed as integral features of the same sheet, eliminating the need for separate flapper and nozzle parts and their associated sealing requirements.
2Reliability
If multiple separate parts are used in conventional servo valves, then assembly flexibility is provided, but the number of potential failure points and leakage issues increases
Solution Approach 1:
The flapper and nozzle are merged into a single monolithic component formed from one sheet of metal through cutting and folding operations. This integration eliminates multiple joints and sealing interfaces that would otherwise be potential failure points for leakage.
3Manufacturing precision
If precise manufacturing and calibration of multiple parts is performed, then operational precision is achieved, but manufacturing time and cost increase
Solution Approach 1:
By forming the flapper and nozzle as a single integrated component from one sheet, the patent eliminates the need for separate manufacturing and calibration processes for each part. The single-component structure ensures precise geometric relationships between flapper and nozzle features without requiring post-assembly calibration.
4Weight of moving object
If conventional flapper and nozzle structures are used, then fluid flow control is achieved, but the assembly is bulky and heavy
Solution Approach 1:
The patent uses a thin sheet of metal that is cut and folded to form both the flapper and nozzle structures. This approach creates a compact, lightweight component that provides the necessary fluid flow control functionality without the bulk of traditional multi-part constructions.
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 more reliable, responsive, and cost-effective servo valve design that can handle high fluid flows and frequencies with fewer parts, improved precision, and reduced manufacturing complexity, while maintaining compactness and accuracy.
Implementation Method 1
An integral flapper and nozzle structure formed from a single sheet of metal, where the flapper, nozzles and orifices are cut using precise techniques like laser cutting
Data Source
Figure 1~2
Figure 3A~4B
Figure 4C~5
AI summary
An integral flapper and nozzle structure for a servo valve assembly whereby the flapper, orifices and nozzles are formed by sheets of metal formed into a single component.