Air-Operated Magnetic Directional Control Valve

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Solution Overview

Problem

Control valves with mechanical springs face issues such as wear and tear, leading to reduced performance and the need for costly and time-consuming replacements, as they wear out and shed particles, causing the spool to remain in intermediate positions.

Innovation Solution

The use of a pair of magnets, such as permanent and electromagnets, arranged to exert a net force on the spool, preventing it from staying in intermediate positions and biasing it towards specific operational positions, thereby eliminating mechanical wear associated with springs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical springs are used to bias the spool toward operational positions, then the spool can be prevented from remaining in intermediate positions, but the springs wear out over time and shed particles, reducing reliability

Engineering Contradiction:

Improvecontrol valve performanceVSAvoidspring service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces mechanical springs with magnetic fields to bias the spool. Electromagnets mounted on the valve body can be selectively activated to exert magnetic forces on the spool, preventing it from remaining in intermediate positions without the mechanical wear and particle shedding associated with spring-based systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces magnetic fields as an intermediary between the control system and the spool. The electromagnets create magnetic fields that interact with magnetic elements on the spool, providing a non-contact mechanism to bias the spool toward operational positions and eliminate the need for direct mechanical contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If springs are used to bias the spool, then operational positions can be maintained, but replacement of worn springs requires disassembly and reassembly, increasing maintenance time and cost

Engineering Contradiction:

Improvespool positioningVSAvoidmaintenance time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The electromagnet system eliminates the need for replaceable mechanical springs. The electromagnetic biasing mechanism is integrated into the valve body and does not require disassembly or replacement, significantly reducing maintenance time and cost while maintaining the ability to bias the spool toward operational positions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electromagnet system is designed to be maintenance-free, with no moving parts that wear out. The electromagnetic components are integrated into the valve body and can operate for the lifetime of the valve without requiring service, making the system self-sufficient and eliminating maintenance downtime.

Inventive Principle:

Principle #25Self-service

3Reliability

If mechanical springs are used to prevent intermediate positions, then control effectiveness is improved, but mechanical contact causes wearing and particle shedding

Engineering Contradiction:

Improvecontrol valve effectivenessVSAvoidparticle shedding

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces mechanical spring contact with magnetic field interaction. The electromagnets create magnetic forces that act on magnetic elements mounted on the spool without physical contact, preventing intermediate positions while eliminating the mechanical wear and particle shedding that occurs with spring-based systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Magnetic fields serve as an intermediary force between the electromagnets and the spool. This non-contact interaction provides the necessary biasing force to maintain operational positions without the harmful mechanical contact that causes particle shedding and contamination in spring-based systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively prevents the spool from remaining in intermediate positions, enhancing control valve performance and reducing maintenance costs by eliminating the need for spring replacements, while providing bidirectional biasing without mechanical wear.

Implementation Method 1

a magnetic element connected to the spool and responsive to a magnetic field such that the spool is biased in a first direction when the spool is in the first position and the spool is biased in a second direction when the spool is in the second position

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS9989164B1Air-operated, magnetic, non-stall air directional control valve

Publication Date: 2018.06.05 TREBOR INTERNATIONAL INC

AI summary

In one example, a valve includes a body defining a chamber, and a spool disposed in the chamber and configured to move within the chamber, such that a first operating position of the valve is defined when the spool is in a first position in the chamber, and a second operating position of the valve is defined when the spool is in a second position in the chamber. The valve also includes a magnetic element connected to the spool and responsive to a magnetic field such that the spool is biased in a first direction when the spool is in the first position and the spool is biased in a second direction when the spool is in the second position, and the second direction is different from the first direction.