Proportional Flow Control Valve With Integrated Pressure Compensation
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Solution Overview
Problem
Conventional hydraulic valves face challenges with high flow forces that require large solenoid coils and increased actuation forces, leading to higher costs and complexity due to opposing flow forces.
Innovation Solution
The implementation of a proportional flow control valve with an integrated pressure compensator, featuring a pressure compensation spool, throttling spool, and pressure compensation chamber, which reduces flow forces by allowing fluid to flow through a throttling flow area and pressure compensation flow area, enabling fluid to be apportioned between bypass and priority ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional hydraulic valves are used, then the valve can direct fluid flow, but large solenoid coils and increased actuation forces are required to overcome opposing flow forces
Solution Approach 1:
The valve is segmented into multiple functional components: a pressure compensation spool, a throttling spool, and separate flow paths (priority port and bypass port). This segmentation allows the pressure compensation spool to handle flow force compensation independently, reducing the burden on the solenoid actuator and enabling a smaller solenoid coil to suffice.
Solution Approach 2:
The pressure compensation spool acts as an intermediary element that introduces a counterbalancing fluid force to offset the opposing flow forces. By using fluid pressure as a mediator, the system reduces the mechanical force requirement on the solenoid actuator, thereby reducing solenoid coil size and complexity.
2Reliability
If larger solenoid coils are used to overcome flow forces, then the valve can operate reliably, but the cost of the valve increases
Solution Approach 1:
The pressure compensation spool serves as an intermediary that uses fluid pressure to generate a counterbalancing force, reliably offsetting opposing flow forces without requiring expensive, large solenoid coils. This maintains valve operation reliability while reducing manufacturing cost.
Solution Approach 2:
The invention employs hydraulic principles by using the fluid itself to generate the counterbalancing force through the pressure compensation spool. This hydraulic approach is more cost-effective than using large electromagnetic solenoid coils, as it leverages the existing fluid pressure in the system.
3Force
If the pressure compensation spool moves in the distal direction, then flow forces are reduced, but the spool must be precisely controlled to maintain proportional flow control
Solution Approach 1:
The pressure compensation spool position is automatically adjusted based on the balance between fluid forces acting upon it. As the spool moves, it changes the pressure compensation flow area, which in turn affects the fluid forces, creating a self-regulating feedback mechanism that maintains precise proportional flow control while reducing flow forces.
Solution Approach 2:
The system dynamically changes the pressure compensation flow area parameter as the spool moves in the distal direction. This parameter change allows the valve to reduce flow forces while maintaining proportional flow control, as the varying flow area compensates for changes in fluid forces.
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 reduces flow forces, allowing for the use of smaller, less expensive solenoid coils and actuators, while maintaining proportional flow control and pressure compensation, thus enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
a pressure compensation spool configured to be subjected to a first fluid force of fluid received at an inlet port of the valve acting on the pressure compensation spool in a proximal direction
Implementation Method 2
the throttling spool moves in the proximal direction to form a throttling flow area between a distal end face of the throttling spool and an edge of the at least one throttling cross-hole, allowing fluid flow from the inlet port to the pressure compensation chamber through the throttling flow area
Implementation Method 3
causing a second fluid force to be applied on the pressure compensation spool in a distal direction by fluid in the pressure compensation chamber, such that the pressure compensation spool moves in the distal direction to form a pressure compensation flow area
Data Source
AI summary
An example valve includes: a pressure compensation spool configured to be subjected to a first fluid force of fluid received at an inlet port of the valve; a sleeve having a cavity and at least one throttling cross-hole; a throttling spool disposed in the cavity of the sleeve and configured to be axially movable therein, wherein the throttling spool blocks the at least one throttling cross-hole when the valve is unactuated; and a pressure compensation chamber, wherein when the valve is actuated, the throttling spool moves in the proximal direction to form a throttling flow area between a distal end face of the throttling spool and an edge of the at least one throttling cross-hole, allowing fluid flow from the inlet port to the pressure compensation chamber, thereby causing a second fluid force to be applied on the pressure compensation spool, allowing flow to an outlet port of the valve.