High-Flow Valve Diaphragm Balancing for Lower Solenoid Power
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High flow cartridge valves require large solenoid magnetic forces, resulting in extensive power usage, large, heavy, and expensive valve assemblies.
Innovation Solution
A high flow valve design that uses a diaphragm with inner and outer bands to balance forces, reducing the need for a large solenoid magnetic force, and eliminates the need for an adjustable pole piece by over-pressing the valve seal to set the initial air gap.
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 rates, but the power consumption increases and the valve assembly becomes larger and heavier
Solution Approach 1:
The valve seal is over-pressed during assembly to pre-set the initial air gap between the armature and pole piece. This preliminary action eliminates the need for large solenoid forces during operation, as the pre-established gap allows the solenoid to operate more efficiently with reduced power consumption while maintaining high flow rates.
Solution Approach 2:
The initial air gap parameter is precisely controlled through over-pressing the valve seal during assembly. By optimizing this gap parameter, the solenoid magnetic force required to initiate valve movement is minimized, thereby reducing power consumption while preserving the valve's high flow capability.
2Productivity
If a large solenoid magnetic force is used to initiate valve position shift, then the valve can achieve high flow rates, but the valve assembly becomes larger and heavier
Solution Approach 1:
The valve seal is over-pressed during assembly to pre-set the initial air gap between the armature and pole piece. This preliminary action eliminates the need for large solenoid forces during operation, thereby allowing for a smaller, lighter solenoid and overall valve assembly while maintaining high flow rates.
Solution Approach 2:
The initial air gap parameter is precisely controlled through over-pressing the valve seal during assembly. By optimizing this gap parameter, the solenoid magnetic force required to initiate valve movement is minimized, allowing for a more compact and lighter valve assembly design that still achieves high flow rates.
3Use of energy by moving object
If an adjustable pole piece is used to set the initial air gap, then the solenoid magnetic force can be optimized, but the device complexity and manufacturing cost increase
Solution Approach 1:
The adjustable pole piece is eliminated from the valve assembly. Instead, the initial air gap is set by over-pressing the valve seal during assembly, which is a simpler, fixed structure. This extraction of the adjustable component reduces device complexity and manufacturing cost while maintaining solenoid power efficiency through the pre-set optimal gap.
Solution Approach 2:
The valve seal itself performs the function of setting the initial air gap through over-pressing during assembly. This self-service approach eliminates the need for separate adjustable pole pieces or complex adjustment mechanisms, thereby reducing device complexity while achieving optimal solenoid power efficiency.
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 design achieves a smaller, lighter, and less expensive valve assembly while maintaining high flow rates, using less power and reducing mechanical shifting noise.
Implementation Method 1
Many cartridge valves use a solenoid magnetic force to initiate a shift in valve position
Implementation Method 2
A high flow valve design that uses a diaphragm with inner and outer bands to balance forces
Implementation Method 3
eliminates the need for an adjustable pole piece by over-pressing the valve seal 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 seat pressure force to balance the exhaust seal pressure force.