Hydraulic Control Valve with Segmented Piston Collars
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Solution Overview
Problem
Existing hydraulic control valves are complex and inefficient in adapting to different phases of piston movement, particularly during rapid forward travel and subsequent holding phases, due to mismatched control edge sizes that affect hydraulic clamping and fluid flow management.
Innovation Solution
The control valve design features recessed control edges on piston collars, with a feedback control edge for high-speed travel and a pressure relief control edge for holding phases, both dimensioned appropriately to manage volume flows effectively, and includes a check valve for precise fluid routing and pressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single control edge is used for both feedback and pressure relief during the entire working stroke, then the control valve structure is simplified, but the hydraulic clamping precision deteriorates because the control edge cannot be optimally dimensioned for both high-speed travel and holding phases
Solution Approach 1:
The control piston is segmented into multiple piston collars (first, second, and third piston collars), each with dedicated control edges. The first piston collar has a first control edge for feedback during high-speed travel, the second piston collar has a second control edge for pressure relief during holding phase, and the third piston collar has a third control edge for return flow. This segmentation allows each control edge to be optimally dimensioned for its specific function, resolving the contradiction between structural simplicity and clamping precision.
Solution Approach 2:
Different control edges on different piston collars are given different local qualities through varying dimensions. The first control edge is dimensioned for high flow during rapid travel, while the second control edge is dimensioned for precise flow control during holding phase. This local differentiation of control edge properties enables precise hydraulic clamping adapted to each working phase without requiring a single oversized complex structure.
2Productivity
If control edges are dimensioned for high-speed travel, then fluid flow management during rapid piston movement is improved, but hydraulic clamping during the subsequent holding phase deteriorates due to excessive control edge size
Solution Approach 1:
The control function is segmented across three piston collars, allowing the first control edge to be optimized for rapid travel flow while the second control edge is optimized for holding phase precision. Each piston collar operates independently in its designated phase, eliminating the compromise that would result from using a single control edge dimensioned for high-speed travel.
Solution Approach 2:
The control valve dynamically adapts to different working phases through the sequential engagement of different piston collars. During rapid travel, the first piston collar's control edge is active with its larger flow capacity. During the holding phase, the second piston collar's control edge becomes active with its precisely dimensioned smaller opening, providing the necessary flow restriction for stable hydraulic clamping.
3Manufacturing precision
If control edges are dimensioned for holding phase, then hydraulic clamping precision during slow travel is improved, but fluid flow management during rapid piston movement deteriorates due to insufficient control edge size
Solution Approach 1:
The control piston is divided into multiple collars with different control edges sized for different phases. The first control edge on the first piston collar is sized for high flow during rapid travel, while the second control edge on the second piston collar is sized for precise flow control during holding phase. This segmentation eliminates the need to compromise either phase's performance.
Solution Approach 2:
The system dynamically switches between different control edges based on the working phase. During rapid piston movement, the first control edge handles the high flow volume. When transitioning to the holding phase, the second control edge takes over with its precisely dimensioned opening, dynamically adapting the flow control characteristics to match the current operational requirements.
4Manufacturing precision
If multiple piston collars with different control edges are used for different working phases, then hydraulic clamping precision across all phases is improved, but the control valve structure becomes more complex
Solution Approach 1:
Multiple control edges for different working phases are merged into a single integrated control piston structure with three piston collars. This unified design allows all control edges to be actuated by a single piston movement, coordinating the switching between feedback, pressure relief, and return flow functions without requiring separate control mechanisms, thus limiting the increase in overall structural complexity.
Solution Approach 2:
The control piston serves multiple functions through its three piston collars: the first piston collar controls feedback flow during high-speed travel, the second piston collar controls pressure relief during holding phase, and the third piston collar controls return flow. This multi-functionality is achieved within a single control piston component, providing precise hydraulic clamping across all phases while avoiding the need for multiple separate control devices.
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 ensures precise hydraulic clamping and simplified fluid management across all working phases, improving the control valve's efficiency and reducing complexity compared to prior art.
Implementation Method 1
hydraulic control valve for controlling a double-acting working cylinder
Implementation Method 2
fluid displaced from the small cubic capacity when the piston rod is extended is fed back into the large cubic capacity
Implementation Method 3
a non-return valve with a flow direction switched on
Implementation Method 4
for the stroke-independent switchover of the working cylinder from the working stroke to slow travel
Data Source
Figure 1
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Figure 3
AI summary
The valve (20) has a pump connection (P), a consumer connection (A1) for supply and discharge lines for a large swept volume of a double-action operating cylinder (10), another consumer connection (B) for supply and discharge lines for a small swept volume of the cylinder and a tank connection (T1) connected to a tank (17). A recess (34) forming a pressure discharge control edge is laid out in a piston collar (31) on fluid flow that is squeezed out of the small swept volume of the cylinder during slow movement, and exhibits dimension smaller than remaining recesses (32, 33) of the collar.