Hydraulic Valve Module Deactivation Without a Return Spring
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Solution Overview
Problem
Hydraulic valves in construction and agricultural machinery face challenges with return springs, which increase costs, require additional space, and lead to energy losses due to the need for powerful motors to overcome spring force, while also being unreliable in harsh conditions like vibrations.
Innovation Solution
A hydraulic valve module using an electric actuator with a controller and energy store to move the valve slide into a deactivation position without a return spring, utilizing a stepper motor or brushless motor for precise positioning and an emergency deactivation mechanism to ensure reliable operation even in power failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a return spring is used to bring the valve slide into rest position, then reliable deactivation is ensured, but device complexity and cost increase due to additional components
Solution Approach 1:
The patent removes the return spring from the hydraulic valve system entirely. Instead of using a mechanical spring to return the valve slide to rest position, the system relies on the natural hydraulic pressure differential and the electric actuator's ability to position the valve slide without spring assistance, thereby simplifying the device structure while maintaining reliability
Solution Approach 2:
The patent replaces the mechanical return spring system with an electrically-controlled actuation system. The electric actuator uses electrical signals to position the valve slide, substituting the mechanical spring force with an electromagnetic or electric motor-driven mechanism, which reduces mechanical complexity while enabling precise control
2Reliability
If a return spring is installed to ensure safe deactivation, then safety is improved, but installation space requirements increase
Solution Approach 1:
The return spring is completely extracted from the valve assembly, eliminating the space it would occupy within the compact hydraulic valve housing. This allows for more compact valve design and better integration into space-constrained applications like construction and agricultural machinery
3Power
If a powerful motor is used to overcome spring force, then valve positioning capability is improved, but energy consumption increases
Solution Approach 1:
The patent replaces the spring-mechanical system with an electric actuator that uses controlled electrical energy to position the valve slide. The electric actuator only consumes energy when positioning or holding the valve in a specific position, rather than continuously opposing spring force, significantly reducing overall energy consumption while maintaining adequate positioning power
Solution Approach 2:
The electric actuator operates in a periodic or intermittent manner, activating only when valve position changes are required, rather than continuously engaging to counteract spring force. This periodic operation reduces average energy consumption while maintaining the ability to quickly position the valve when needed
4Power
If the actuator is designed to move valve stem against spring force, then positioning capability is improved, but overall energy losses increase
Solution Approach 1:
The patent eliminates the spring force that the actuator would need to overcome by removing the spring entirely. The electric actuator only needs to overcome friction and hydraulic resistance, not spring force, significantly reducing energy losses while maintaining full positioning capability across the valve's operating range
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 solution reduces the size and energy consumption of the actuator, eliminates the need for a return spring, and ensures reliable operation and quick restarts of hydraulic valves, even in harsh conditions, by using an electric actuator and energy store for deactivation and calibration.
Implementation Method 1
an electric actuator with a controller and energy store to move the valve slide into a deactivation position without a return spring, utilizing a stepper motor or brushless motor for precise positioning
Implementation Method 2
A hydraulic valve module has at least one hydraulic valve with a valve slide, wherein the valve slide can be adjusted by way of an electric actuator... wherein the hydraulic valve module has a controller and an electric energy store
Data Source
AI summary
Techniques involve a hydraulic valve module having at least one hydraulic valve with a valve slide which can be adjusted by way of an electric actuator in order to supply hydraulic lines with hydraulic liquid by way of the hydraulic valve. The hydraulic valve module has a controller and an electric energy store. The controller and the electric energy store are set up to move the valve slide out of every possible valve slide position into a deactivation position by way of the electric actuator and energy which is stored in the electric energy store. This allows the safe operation of hydraulic valves without a restoring spring, wherein valves of this type and the actuators thereof can be of smaller and less expensive construction than in the case of conventional valves with a restoring spring.