Hydromechanical Linear Converter Valve for High-Pressure Sealing
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Solution Overview
Problem
Hydromechanical linear converters face limitations in economy, energy efficiency, compactness, and process optimization, particularly in achieving reliable sealing and efficient operation at high pressures without excessive electromagnetic actuator load.
Innovation Solution
A hydromechanical linear converter design incorporating a valve unit with a spring-preloaded valve body, an electromagnetic actuator, and a hydraulic operating chamber that uses hydraulic force for sealing, allowing reliable shut-off even at high pressures and enabling self-retention of the second switching position without continuous electromagnetic actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If an electromagnetic actuator is used to switch the valve unit, then the switching speed and responsiveness are improved, but the actuator must withstand high pressures which increases its size and energy consumption
Solution Approach 1:
The patent replaces the conventional electromagnetic actuator that directly withstands high pressure with a hydraulic amplifier system. The electromagnetic actuator only needs to overcome low spring preload force to open the valve, while the hydraulic pressure differential (high pressure from hydraulic chamber vs. low pressure from spring) provides the sealing force in closed position. This substitution allows the electromagnetic actuator to operate at low force requirements while maintaining high-speed switching capability.
Solution Approach 2:
The patent employs hydraulic pressure differential to amplify the switching action. The hydraulic chamber connected to the actuator experiences high pressure that acts on a large surface area of the valve body, creating a force that assists the electromagnetic actuator in opening the valve. Conversely, when closed, the spring preload combined with the pressure differential provides reliable sealing without requiring the electromagnetic actuator to continuously counteract high pressure.
2Reliability
If the electromagnetic actuator continuously holds the valve in the second switching position, then reliable sealing at high pressure is achieved, but energy consumption increases
Solution Approach 1:
The patent implements a self-latching mechanism where the valve body's position is maintained by the spring preload force in the closed position (second switching position). The electromagnetic actuator only needs to provide a brief pulse to overcome the spring force and open the valve (first switching position). Once opened, the valve remains open due to the pressure differential and flow dynamics. This eliminates the need for continuous electromagnetic actuation, significantly reducing energy consumption while maintaining reliable sealing when closed.
Solution Approach 2:
The electromagnetic actuator operates in periodic pulse mode rather than continuous operation. It delivers short-duration electrical pulses to switch the valve between positions, with the valve maintaining its position through mechanical spring force and hydraulic pressure balance. This periodic actuation pattern reduces average power consumption while ensuring reliable sealing during the closed state through the spring-preloaded valve body.
3Reliability
If a large electromagnetic actuator is used to ensure reliable shut-off at high pressures, then sealing reliability is improved, but the device complexity and size increase
Solution Approach 1:
The patent replaces the need for a large, high-force electromagnetic actuator with a compact actuator that only needs to overcome a relatively weak spring preload force. The sealing reliability at high pressure is achieved not by the actuator's direct force, but by the spring-preloaded valve body design combined with hydraulic pressure differential. This substitution dramatically reduces the electromagnetic actuator's size and complexity while maintaining or improving shut-off reliability.
Solution Approach 2:
The patent changes the operating parameters of the valve switching system by decoupling the sealing force generation from the electromagnetic actuator. Instead of requiring the actuator to generate high closing force, the system uses spring preload force and hydraulic pressure differential to provide the sealing action. This parameter change allows the use of a small, simple electromagnetic actuator while achieving reliable high-pressure shut-off through the spring-preloaded valve body design.
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 configuration enhances economic efficiency, energy efficiency, compactness, and process optimization by reducing the electromagnetic actuator's workload, allowing for reliable operation at low system pressures and extending machine service life.
Implementation Method 1
a spring unit which preloads the valve body into a position corresponding to the first switching position of the valve unit, in which its valve head is lifted from the valve seat
Implementation Method 2
an electromagnetic actuator acting on the valve body via a purely mechanical actuation chain and by means of which the valve body can be adjusted against the force of the spring unit
Implementation Method 3
the valve body is sealingly guided in the valve housing in such a way that together with the latter it delimits a hydraulic operating chamber which communicates hydraulically with the fluid connection via a compensation channel and the pressurisation of which acts on the valve body in the opposite direction to the spring unit
Implementation Method 4
the surface portions of the valve body limiting the hydraulic operating chamber are larger than those surface portions of the valve body exposed to the pressure prevailing in the fluid connection in the second switching position of the valve unit, the pressurization of which acts on the valve body in the same direction as the spring unit
Data Source
AI summary
A hydromechanical linear converter has a cylinder, a piston unit and a seat valve unit. The cylinder and a piston of the piston unit delimit a hydraulic working chamber, into which a working connection and a further fluid connection open, and has a supply connection 10. The valve unit switches between a first position connecting the supply connection to the fluid connection and a second position blocking the fluid connection from the supply connection. The linear converter includes a valve housing with a valve seat 16, a valve body with a valve head cooperating with the seat, a spring unit preloading the valve body into a position corresponding to the first position and an electromagnetic actuator 14 acting on the valve body 12 by purely mechanical action, to move the valve body against the force of the spring unit into a position corresponding to the second switching position.