Micro Pilot Valve Design for Rapid Switching and Zero Air Consumption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional micro pilot valves suffer from long switching times and permanent air consumption due to tolerances and contaminations in the throttle, making it difficult to achieve precise control pressure levels and high switching frequencies.
Innovation Solution
A micro pilot valve design featuring a micro cavity with two micro openings and a movable sealing element actuated by a micro actuator, allowing for rapid switching between two supply pressure levels with minimal dead volume and no permanent air consumption, enabling switching times under 0.1 milliseconds and frequencies above 5 kHz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a series circuit with a micro valve and pneumatic throttle element is used to control pressure, then the valve can amplify small switching energy, but the pressure level varies due to tolerances and contaminations of the throttle
Solution Approach 1:
The patent removes the pneumatic throttle element from the system entirely. Instead of using a series circuit with a micro valve and throttle, the invention uses a micro pilot valve with a micro cavity that directly connects two pressure levels through micro openings, eliminating the source of pressure variation caused by throttle tolerances and contaminations.
Solution Approach 2:
The patent segments the control volume into a small micro cavity with defined micro openings to each pressure level. This segmentation allows precise control of pressure levels by isolating the control volume from the effects of throttle element variations, enabling exact settlement at two defined pressure levels.
2Measurement precision
If an open valve in the series circuit is used, then pressure control is possible, but permanent air consumption occurs
Solution Approach 1:
The micro pilot valve operates with periodic switching between two discrete states (open to first pressure level or open to second pressure level), rather than maintaining a continuously open state. This periodic action eliminates permanent air consumption while maintaining precise pressure control capability.
Solution Approach 2:
The valve discards the continuous open state that causes permanent air consumption and recovers the ability to achieve precise pressure control through discrete switching states. The micro cavity isolates the control volume so that brief opening events do not result in continuous air loss.
3Power
If conventional micro pilot valves are used, then pressure amplification is achieved, but switching times are long
Solution Approach 1:
The patent uses a nested structure with a micro cavity containing micro openings and a sealing element that can be positioned to block either micro opening. This nested design allows rapid switching by simply moving the sealing element within the confined micro cavity space, achieving switching times under 0.1 milliseconds while maintaining pressure amplification capability.
4Loss of time
If the valve is designed for fast switching, then switching times are reduced, but tolerances and contaminations have greater impact on pressure levels
Solution Approach 1:
The patent replaces the mechanical throttle element with a micro cavity system controlled by a sealing element. This substitution eliminates the tolerance and contamination issues associated with mechanical throttles, allowing fast switching without compromising pressure level accuracy. The micro openings provide precise flow control without the variability of mechanical components.
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
The design achieves precise control pressure levels at two supply pressure levels with extremely short switching times and high frequencies, reducing the impact of tolerances and contaminations, and minimizing air consumption.
Implementation Method 1
a sealing element 8 within micro cavity 2, which is movable between the micro openings, and which in a first end position closes micro opening 4 and in a second end position micro opening 6
Implementation Method 2
a micro actuator 10, which actuates sealing element 8 via a transfer element, which protrudes at least through one of the micro openings
Implementation Method 3
Pilot valves are used to amplify a small switching energy by use of a pneumatic pressure as an auxiliary energy to control processes, which require a higher switching energy
Data Source
AI summary
The invention relates to a micro pilot valve 1, which is characterized by a micro cavity 2, which is connected with valve outlet 3, a first micro opening 4 between micro cavity 2 and a first pressure level 5, a second micro opening 6 between micro cavity 2 and a second pressure level 7, a sealing element 8 within micro cavity 2, which is movable between the micro openings, and which in a first end position closes micro opening 4 and in a second end position micro opening 6, whereas the control pressure in the first end position adopts the value of the second pressure level 7 and in the second end position the value of the first pressure level 5, and a micro actuator 10, which actuates sealing element 8 via a transfer element, which protrudes at least through one of the micro openings.