Layered Electropneumatic Valve Assembly for Switching Time Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electropneumatic valve groups face complexity in production and longer switching times due to the need for complex design and large volumes for control pressure generation, making them costly and inflexible for adapting to different customer-specific requirements.
Innovation Solution
A modular, layered construction of the valve group with a control pressure area between the pilot and power stage housings, allowing for simple adjustment of flow cross-sections and throttling effects through the specific shape and arrangement of the channel-like connection, eliminating the need for separate throttles and enabling flexible adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If straight channels with pressed-in throttles are used for pneumatic control, then switching behavior can be adapted, but production complexity increases and switching times lengthen
Solution Approach 1:
The invention extracts the throttle function from separate pressed-in throttle components and integrates it directly into the housing wall structure. The throttling effect is achieved through constrictions and deflections formed directly in the housing material, eliminating the need for separate throttle parts and their installation processes.
Solution Approach 2:
The housing structure merges multiple functions: it provides mechanical support, creates pneumatic channels, and generates throttling effects all in one integrated component. The channel-like connection with defined flow cross-section combines the functions of pneumatic conduit and flow control element.
2Ease of operation
If long bores are used to accommodate throttles, then switching behavior can be controlled, but control pressure volume increases and switching times lengthen
Solution Approach 1:
Instead of using long linear bores, the invention creates three-dimensionally shaped channels with varying cross-sections. The channel-like connection features constrictions and deflections that provide throttling in a compact volume, transforming the problem from a linear dimension (long bore) to a volumetric dimension (shaped passage).
Solution Approach 2:
The invention changes the flow control parameter from length-based throttling (long bores) to cross-section-based throttling (defined flow cross-sections). By controlling the shape and size of the channel passage rather than its length, switching behavior is achieved with shorter, faster-response channels.
3Manufacturing precision
If complex throttle designs are used for precise switching control, then switching precision improves, but manufacturing cost increases
Solution Approach 1:
The housing material itself provides the throttling function without requiring additional components. The constrictions and deflections are formed directly in the housing, allowing the housing structure to serve its own flow control needs and eliminating the need for separate precision-manufactured throttle parts.
Solution Approach 2:
The invention changes from precision-machined throttle components to molded or formed channel structures. By defining flow cross-sections through shaping processes rather than precision machining of separate parts, manufacturing precision is maintained while cost is reduced.
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 simplifies the adjustment of switching times for power valves, reduces production complexity, and allows for cost-effective manufacturing, making the valve group more adaptable and efficient.
Implementation Method 1
The throttling effect required to influence the switching times of the power valves can therefore be generated within the scope of the present invention in particular by the specific shape and arrangement of the control pressure area formed between the pilot stage housing and the power stage housing
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An electropneumatic valve assembly (1) comprises an electropneumatic pilot stage with at least one pilot valve (P1) and comprises a pneumatic power stage which is actuated by the pilot stage. Here, each pilot valve switches at least two power valves (L1a; L2b) which are coupled pneumatically to the pilot valve, and the valve assembly (1) has a housing with an electrical signal input, with a compressed-air port (18), with at least one vent port and with at least one working outlet. The housing is of layered construction with at least one pilot stage housing (3) and with at least one power stage housing (4) which is connected to said pilot stage housing along a substantially planar parting surface (T). Here, at least one sealing element (D1, D2) is received or formed between the at least one pilot stage housing (3) and the at least one power stage housing (4), which at least one sealing element surrounds a control pressure region (S1, S2) arranged between the pilot stage housing (3) and power stage housing (4). Said control pressure region has two actuation regions (A1a; A2b) for two power valves (L1a; L2b) and has a duct-like connection with a defined flow cross section between the two actuation regions. Also, an outlet (14), provided in the pilot stage housing (3), of the associated pilot valve (P1) opens into the control pressure region (S1, S2).