Modular Hydraulic Valve Electronics for Fast Module Replacement
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Solution Overview
Problem
Existing hydraulic valve assemblies have maintenance and replacement challenges due to integrated valve electronics within the housing, requiring complex disassembly and potential dirt ingress, and are expensive due to all functions being housed in the electronics, leading to limited functionality upon failure.
Innovation Solution
A hydraulic valve assembly with a connection block and detachable main and valve section electronics modules, allowing easy access and replacement, using an electrical backbone for communication and power, and incorporating wireless interfaces for simplified maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If valve electronics are integrated within the housing, then functionality is consolidated, but maintenance and replacement become complex requiring disassembly and risking dirt ingress
Solution Approach 1:
The electronics are segmented into separate modular units (main electronics module and valve section electronics modules) that can be independently accessed and replaced. Each valve section has its own electronics holder that can be detached without disassembling the entire housing, enabling easy maintenance while maintaining functional consolidation through modular architecture.
Solution Approach 2:
The electronics modules are extracted from the traditional integrated housing structure and placed in separate, easily accessible holders. The main electronics module is mounted on the connection block while valve section electronics are in separate holders, allowing them to be removed and replaced without complex disassembly or risk of dirt ingress into the hydraulic system.
2Adaptability or versatility
If all functions are housed in the electronics, then integration is achieved, but cost increases and functionality is limited upon failure
Solution Approach 1:
The electronic functions are segmented into different modules: a main electronics module containing computing-intensive tasks and a main control unit, and separate valve section electronics modules containing secondary control units. This segmentation allows selective replacement of only the failed module rather than requiring replacement of the entire electronic system, reducing costs while maintaining integration through the electrical backbone connection.
Solution Approach 2:
The system allows for different configuration parameters of electronics modules to be selected based on application requirements. Valves can be equipped with or without secondary control units, position sensors, or specific actuating units, enabling cost optimization by including only the necessary functions rather than all possible functions in every unit.
3Volume of stationary object
If electronics are integrated in housing, then system compactness is achieved, but replacement time increases causing downtime
Solution Approach 1:
The electronic system is segmented into independently accessible modules mounted on the connection block and valve sections. Each module has its own holder with connection interfaces that allow quick attachment and detachment. This segmentation enables replacement of individual electronics modules without affecting other parts of the compact hydraulic system, significantly reducing replacement time while maintaining system compactness.
Solution Approach 2:
The electronics modules are pre-configured with all necessary connections and interfaces before installation. The electrical backbone is pre-routed within the hydraulic system, and connection interfaces are pre-positioned on the connection block and valve sections. This preliminary preparation allows modules to be quickly swapped without requiring complex assembly or disassembly operations during maintenance.
Data Source
AI summary
The present invention relates to a hydraulic valve assembly (10) with a connection block (12) and at least one valve section (14.1 . . . 14.n), wherein the hydraulic valve assembly (10) comprises a main electronics holder (16) with a main electronics module (18) disposed therein, and wherein the valve section (14.1 . . . 14.n) comprises a valve section electronics holder (20.1 . . . 20.n) with a valve section electronics module (22.1 . . . 22.n) disposed therein