Hydraulic Flow Control Valve with Stepper Motor and Rack-Pinion Actuation
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Solution Overview
Problem
Hydraulic lifting installations face challenges in achieving both safety and precise control with existing flow control valves, leading to increased complexity and cost due to the need for multiple components.
Innovation Solution
A flow control valve using a stepper motor and a reversible kinematic pair with a spring mechanism to maintain valve position during power failures, combined with a magnetic sensor for calibration and a three-way pilot electrovalve for fluid pressure control, simplifies the design while ensuring safety and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple normally closed valves are provided to ensure safety, then safety is improved, but device complexity increases
Solution Approach 1:
The patent combines the safety check valve function and the flow control function into a single integrated valve body. The slider mechanism simultaneously performs flow regulation and safety checking, eliminating the need for separate safety valves while maintaining both functions.
Solution Approach 2:
The valve is designed to perform multiple functions: flow control through slider positioning, safety check valve operation through the reversible kinematic pair, and automatic reset capability. This multi-functionality reduces the total number of components needed in the hydraulic system.
2Manufacturing precision
If a stepper motor with screw transmission is used for precise flow control, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces the traditional screw transmission mechanism with a reversible kinematic pair (rack and pinion). This substitution maintains the precision of slider positioning while simplifying the mechanical structure and eliminating the need for complex screw threads and associated components.
3Reliability
If resilient means are used to prevent uncontrolled emptying, then reliability is improved, but the valve may not remain open during power failures
Solution Approach 1:
The patent employs a reversible kinematic pair that allows the slider to maintain its position dynamically during power failures. The mechanism can be moved in both directions and will hold position without continuous power, enabling the valve to remain open or closed based on the last commanded position even when power is lost.
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 solution provides precise flow control and safety features, such as preventing uncontrolled fluid return, with reduced component complexity and lower costs, enabling efficient operation of hydraulic lifting systems.
Implementation Method 1
the use of a reversible pair allows the resilient means - preferably consisting of a simple spring - to exert their action on the slider in the absence of a power supply
Implementation Method 2
at least one magnetic sensor for detecting at least one position from among the fully open position and fully closed position of the flow control valve
Data Source
Figure 1~1a
Figure 2
Figure 3
AI summary
Flow control valve (101) for a hydraulic control circuit of a lifting installation, comprising a slider (102) slidably movable inside a valve body (103) between a fully open valve position and a fully closed valve position, so as to regulate the flow which passes through the flow control valve (10), further comprising an electric stepper motor acting on said slider (102) by means of a reversible pair (105, 106), preferably a pinion (105) on the motor side meshing with a rack (106) integral with said slider (102), and resilient means (107) also acting on said slider (102) and designed to move it into and/or keep it in the fully closed valve position in the absence of the power supply to the electric stepper motor (104).