Hydraulic Valve Block Flow Channel Layout for Lower Pressure Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Machined hydraulic valve blocks experience increased pressure loss, vibration, noise, and reduced structural reliability and service life due to their complex internal structures, which include 90° right-angle cross pore passages and fabrication holes, limiting their efficiency and durability.
Innovation Solution
A method utilizing selective laser melting to design and manufacture hydraulic valve blocks by optimizing flow channels to reduce pressure loss and weight, involving topology optimization of solid portions to create a three-dimensional solid structure model, which is then printed using selective laser melting, thereby improving flow efficiency and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional machining methods are used to create hydraulic valve blocks with complex internal structures, then the structural strength is maintained, but the pressure loss increases and flow efficiency decreases
Solution Approach 1:
The patent inverts the traditional design approach by designing flow channels from the liquid flow path perspective rather than from the solid structure perspective. This allows optimization of flow efficiency while maintaining structural strength, reducing pressure loss by 25% compared to traditional machining methods.
Solution Approach 2:
The patent transitions from two-dimensional cross-sectional design to three-dimensional spatial design of flow channels. By considering the spatial distribution and connectivity of channels in 3D space, the design achieves better flow efficiency and reduced pressure loss while maintaining structural requirements.
2Weight of moving object
If traditional machining methods are used, then manufacturing precision is achieved, but the weight of the valve block increases
Solution Approach 1:
The patent changes the manufacturing method from traditional machining to additive manufacturing (selective laser melting). This parameter change enables weight reduction by 40% while maintaining flow channel precision, as additive manufacturing can directly create complex 3D structures without the material removal limitations of machining.
3Reliability
If complex internal structures with 90° right-angle cross pore passages are created, then the flow channel connectivity is ensured, but the structural reliability decreases due to vibration, noise and cavitation
Solution Approach 1:
The patent replaces 90° right-angle passages with curved flow channels that have smooth transitions. This eliminates sharp corners where cavitation and turbulence occur, reducing vibration, noise and cavitation while maintaining flow connectivity. The curved channels improve structural reliability by eliminating stress concentration points.
4Weight of moving object
If selective laser melting is used to manufacture hydraulic valve blocks, then weight reduction is achieved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing steps into a single additive manufacturing process. The flow channel design integrates structural elements and flow paths that would require separate machining operations, allowing weight reduction by 40% while consolidating manufacturing complexity into one process step.
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 method effectively reduces pressure loss by 25% and weight by 40%, enhancing liquid flow efficiency and reducing energy consumption while maintaining structural strength and service life, allowing for complex structure manufacturing without increasing material usage.
Implementation Method 1
printing the three-dimensional solid structure model by using selective laser melting to obtain the hydraulic valve block
Data Source
AI summary
The present disclosure provides a method of designing and manufacturing a hydraulic valve block based on selective laser melting. The method includes providing a machined hydraulic valve block, determining whether the machined hydraulic valve block needs weight reduction, if the machined hydraulic valve block needs weight reduction, taking reduction of the pressure loss of the flow channel as an optimization goal and optimizing the flow channel of the machined hydraulic valve block to obtain an optimized flow channel structure model, taking reduction of the weight of the hydraulic valve block as an optimization goal and optimizing solid portions of the optimized flow channel structure model by using a topology optimization method to obtain a three-dimensional solid structure model of a hydraulic valve block and printing the three-dimensional solid structure model by using selective laser melting to obtain the hydraulic valve block.