Hydraulic Control Valve Segmentation for Construction Machinery
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Solution Overview
Problem
Existing hydraulic control valves for construction machines require a large-sized spool to control hydraulic fluid flow, increasing manufacturing costs and making them difficult to mount on hydraulic cylinders, while also having inefficiencies in fluid flow control.
Innovation Solution
A hydraulic control valve design that minimizes components by incorporating a valve block with inlet and outlet ports, check valves with throttling portions, and a spool with variable throttling to control fluid flow, allowing for smoother and more precise control of hydraulic fluid from the inlet to the outlet port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large-size spool is used to control hydraulic fluid flow, then the pressure control capability is improved, but the device size and manufacturing cost increase
Solution Approach 1:
The invention divides the hydraulic control function into two independent check valves (first check valve with first throttling portion and second check valve with second throttling portion) instead of using a single large spool. Each check valve handles specific flow control tasks, segmenting the control function to achieve the same pressure control capability with smaller, simpler components.
Solution Approach 2:
The invention combines the functions of flow control and pressure control into the check valve structure itself by integrating throttling portions directly into the check valves. This merging eliminates the need for a separate large spool, as the check valves with built-in throttling portions perform both flow regulation and pressure control functions.
2Reliability
If a large-size spool is used to control hydraulic fluid flow, then the pressure control capability is improved, but the manufacturing cost increases
Solution Approach 1:
The control function is segmented into two independent check valves with throttling portions, replacing the need for a single large, expensive spool. This segmentation allows for smaller, more cost-effective components that can be manufactured more easily while maintaining pressure control capability.
Solution Approach 2:
The invention uses standard check valve components with integrated throttling portions, which are simpler and less expensive to manufacture than a large precision spool. These components are more readily available and cost-effective, reducing overall manufacturing costs while achieving the same functional result.
3Reliability
If a large-size spool is used to control hydraulic fluid flow, then the pressure control capability is improved, but the mounting difficulty increases
Solution Approach 1:
The hydraulic control function is segmented into two separate check valve assemblies, each with its own throttling portion. This segmentation results in smaller individual components that are easier to handle, position, and mount compared to a single large spool assembly, thereby improving ease of installation while maintaining pressure control capability.
Solution Approach 2:
Instead of using a single large moving spool component for control, the invention inverts the approach by using two check valves that respond to pressure differential. This inversion eliminates the need for precise mechanical positioning of a large spool, making the system easier to mount and adjust.
4Device complexity
If check valves are used to control hydraulic fluid flow, then the component size is reduced, but the flow control precision deteriorates
Solution Approach 1:
The invention incorporates dedicated throttling portions (first throttling portion in the first check valve and second throttling portion in the second check valve) that are specifically designed for precise flow control. These localized throttling structures provide accurate flow regulation at critical points in the hydraulic circuit, compensating for the simpler overall check valve design.
Solution Approach 2:
The invention uses the pressure differential across the check valves as a controlling parameter to achieve precise flow control. By designing the check valves to open and close based on pressure conditions, and incorporating throttling portions with specific flow characteristics, the system achieves precise flow control without requiring large or complex components.
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 manufacturing costs, enhances the competitiveness of the control valve, and simplifies its mounting on hydraulic cylinders by minimizing components and improving fluid flow control.
Implementation Method 1
the first check valve C1 is maintained in a closed state by the pressure in the back pressure chamber 5 of the first check valve C1 and the elastic force of a spring 10
Implementation Method 2
the pressure in the back pressure chamber 6 of the second check valve C2 becomes equal to the pressure of the inlet port P1
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A hydraulic control valve for a construction machine is disclosed, which can variably control the flow of hydraulic fluid that is supplied to a hydraulic cylinder to drive a working device. The hydraulic control valve for a construction machine includes a valve block in which an inlet port and an outlet port that communicates with the inlet port is formed, a check valve provided with a first throttling portion to permit the flow of the hydraulic fluid from the inlet port to the outlet port and to variably control the flow of the hydraulic fluid from the outlet port to the inlet port, and a spool provided with a second throttling portion to variably control the flow of the hydraulic fluid from the outlet port to the inlet port through the check valve that is opened when the second throttling portion is shifted by pilot signal pressure.