Hydraulic Pressure Intensifier Valve Flange Design
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Solution Overview
Problem
Existing hydraulic pressure intensifiers face limitations in achieving a large volume output on the high pressure side due to inefficiencies in the switching valve mechanism, leading to increased time for filling and emptying the low pressure chamber and reduced frequency of operation.
Innovation Solution
The hydraulic pressure intensifier incorporates a switching valve with a radially extending flange for the valve element, allowing for a larger control pressure area and minimizing hydraulic losses by keeping the control pressure areas outside the low pressure chamber, and utilizing a pilot valve to control the pressure difference between these areas, which can be either hydraulically or electrically driven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the switching valve is made larger to increase volume flow, then the volume flow into and out of the low pressure chamber is increased, but the time for filling and emptying the low pressure chamber is decreased which increases the frequency of operation
Solution Approach 1:
The valve element is designed with a radially extending flange that creates control pressure areas on opposite faces, utilizing the radial dimension to increase the effective area for pressure control without increasing the axial length of the valve, thereby enabling larger volume flow while maintaining compact dimensions
Solution Approach 2:
A pilot valve is introduced as an intermediary component to control the switching valve. The pilot valve manages the pressure difference across the control pressure areas of the switching valve, enabling precise control of the larger switching valve with a smaller control mechanism, thus achieving high volume flow with efficient time management
2Loss of energy
If the control pressure areas are located outside the low pressure chamber, then hydraulic losses are minimized, but the construction complexity of the housing is simplified
Solution Approach 1:
The control pressure areas are integrated into the flange structure of the valve element itself, merging the control function with the valve body. This eliminates the need for separate control pressure chambers and complex internal channeling, reducing hydraulic losses while simplifying the housing construction to a single machinable piece
3Quantity of substance
If the pilot valve controls a pressure difference between control pressure areas, then the switching valve can be made larger with larger volume flow, but the construction of the pilot valve is simplified
Solution Approach 1:
The pilot valve utilizes the existing pressure differential in the system to control the switching valve. By positioning the control pressure areas on opposite faces of the flange, the system uses the natural pressure distribution to actuate the pilot valve, eliminating the need for additional complex control mechanisms and enabling the switching valve to be larger for high volume flow
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 design enhances the volume flow through the low pressure chamber, decreases the time for filling and emptying, increases the frequency of operation, and allows for precise control of the high-pressure fluid output, while minimizing hydraulic losses and simplifying the construction of the housing.
Implementation Method 1
the pilot valve controls a pressure difference between the first control pressure area and the second control pressure area
Implementation Method 2
force transmitting means between the low pressure chamber and the high pressure chamber
Data Source
Figure 1
Figure 2
AI summary
A hydraulic pressure intensifier (1) is described comprising a housing (2) having a low pressure chamber (3) and a high pressure chamber (4), force transmitting means (5) between the low pressure chamber (3) and the high pressure chamber (4), and a switching valve (8) connecting the low pressure chamber (3) to a first pressure or to a second pressure different from the first pressure. It is intended to have a large volume on the high pressure side of the pressure intensifier. To this end the switching valve (8) is controlled by a pilot valve 18.