Integrated Valve Body Layout for Lightweight Leak-Resistant Flow Paths
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Solution Overview
Problem
Traditional hydraulic valve body manufacturing methods result in issues such as air holes, sand holes, complex structures, high weight, and leakage risks due to cumbersome clamping, geometric tolerance difficulties, and high weight-to-volume ratios, which compromise product quality and safety.
Innovation Solution
A method for designing and manufacturing an integrated valve body using additive manufacturing, where the internal flow channel structure and mounting structures are determined based on hydraulic functions and external device connections, with a work structure supported by an internal connection plane and external shell, reducing redundant parts and weight while improving quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional forging method is used to manufacture valve body, then structural strength is improved, but air holes, sand holes or interlayer phenomenon occur making qualification rate and using safety unreliable
Solution Approach 1:
The patent changes the manufacturing method from traditional forging to additive manufacturing, fundamentally altering the production parameters and process to eliminate defects while maintaining structural integrity. The additive manufacturing process builds the valve body layer by layer, avoiding the air holes, sand holes, and interlayer phenomena associated with forging.
Solution Approach 2:
The patent replaces the mechanical forging process with additive manufacturing technology, substituting a mechanical deformation-based system with a material deposition-based system. This substitution eliminates the harmful effects of traditional forging while achieving the desired structural strength through controlled layer-by-layer construction.
2Manufacturing precision
If traditional machining method is used for valve body processing, then geometric tolerance and surface roughness requirements are met, but the process is cumbersome with difficult clamping and high complexity
Solution Approach 1:
The patent replaces traditional mechanical machining operations with additive manufacturing, eliminating the need for multiple machining stages, clamping operations, and complex tooling setups. The valve body is built directly in the desired geometry, removing the cumbersome machining process entirely.
Solution Approach 2:
The patent segments the manufacturing process into digital design and additive construction phases, separating the complex geometric creation from physical material removal. This allows complex geometries to be achieved through digital modeling followed by direct additive construction, avoiding traditional machining complexities.
3Ease of manufacture
If traditional machining method is used for flow channel processing, then horizontal or vertical hole positions are achieved, but the valve body structure becomes complicated with many process holes and high leakage risk
Solution Approach 1:
The patent inverts the traditional approach by not creating holes through the valve body but rather building the flow channels as integral parts of the additive structure. Instead of drilling holes and risking leakage, the valve body is constructed with embedded flow channels that are inherently leak-proof, eliminating the need for process holes and reducing structural complexity.
Solution Approach 2:
The patent embeds flow channels within the valve body structure during additive manufacturing, nesting the fluid pathways inside the solid material. This creates an integrated structure where the flow channels are contained within the valve body walls, eliminating the need for separate process holes and reducing leakage risk.
4Strength
If traditional forging method is used for valve body, then structural integrity is achieved, but the valve body becomes heavy and bulky with high weight ratio and volume ratio
Solution Approach 1:
The patent changes the manufacturing methodology from forging to additive manufacturing, which allows for optimized material distribution. The additive process enables creation of lightweight internal structures and flow channels that reduce overall weight and volume while maintaining structural integrity through controlled material placement.
Solution Approach 2:
The patent applies local quality by varying material density and structure in different regions of the valve body. Critical load-bearing areas maintain higher material density for strength, while non-critical areas and flow channels use reduced material, achieving optimal strength-to-weight ratio and reducing overall valve body weight and volume.
Data Source
AI summary
An integrated valve is made by a method for designing and manufacturing a valve body of the integrated valve. The method for designing the valve body of the integrated valve includes: determining an internal flow channel structure of a valve body model of the integrated valve according to a hydraulic function implemented by the integrated valve; determining a position and a size of respective mounting structures, matched with the external devices, in the valve body model; determining a work structure of the valve body model according to the internal flow channel structure, and the position and the size of respective mounting structures; determining an internal connection plane of the valve body model, and determining an internal supporting table; and determining an external shell of the valve body model, and connecting the external shell with the work structure and the internal supporting table.