Monolithic Solenoid Valve Block Design for Vibration Resistance
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Solution Overview
Problem
Solenoid operated valves in industrial and aeronautical applications face failure due to high vibration and wear from complex valve blocks with multiple components, leading to imprecision and reduced lifespan.
Innovation Solution
A solenoid operated valve design featuring a monolithic valve block with a unique geometry and fewer assembly components, including a poppet with an enlarged annular seat ring and a solenoid with a novel winding and core structure, which enhances precision and durability by reducing part count and improving force optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a valve block is constructed with multiple components to facilitate assembly of the poppet, then ease of manufacture is improved, but device complexity increases and reliability deteriorates due to wear and tolerance accumulation
Solution Approach 1:
The patent merges multiple valve block components into a single monolithic valve block structure. The poppet assembly is integrated directly into the monolithic block, eliminating separate components and interfaces. This reduces the number of parts from multiple components to a unified structure, thereby improving reliability by eliminating wear at interfaces and accumulation of manufacturing tolerances across multiple parts.
2Reliability
If a monolithic valve block is used to reduce components and improve reliability, then device complexity is reduced and reliability is improved, but ease of manufacture deteriorates due to difficulty in assembling the poppet
Solution Approach 1:
The monolithic valve block is designed with a segmented internal structure that includes a specifically configured lumen with an enlarged portion. This segmentation of the internal space allows the poppet to be assembled from one end of the block, with the enlarged lumen portion providing clearance for the poppet's enlarged portion to be inserted and positioned correctly before being secured in its final operating position.
3Device complexity
If traditional solenoid geometry is used, then device complexity is maintained, but force optimization deteriorates resulting in suboptimal forces when energized
Solution Approach 1:
The solenoid is designed with non-uniform winding distribution, concentrating more turns in the region where the armature is positioned when energized. This local quality variation in the winding density creates a stronger magnetic field precisely where needed to act on the armature, thereby optimizing the force generated without requiring a complete redesign of the entire solenoid structure.
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 significantly reduces the impact of manufacturing tolerances, enhances precision, and increases the operational lifespan of solenoid operated valves by up to 25%, while providing a 20-50% greater force when energized, improving their reliability in vibration-prone environments.
Implementation Method 1
Prior art valves use solenoids that provide forces that are suboptimal when the solenoid is energized
Data Source
AI summary
A solenoid operated valve includes a valve block defining a valve lumen, a poppet slidably disposed within the valve lumen, a solenoid including an annular winding with an internal surface defining a winding lumen and an external surface, and a core including a central core portion disposed within the winding lumen and an annular core portion disposed outside the external surface of the winding, and an armature including a central armature portion disposed within the winding lumen and an annular armature portion disposed outside the external surface of the winding, wherein the armature is in communication with the poppet so that movement of one is translated into movement of the other. Solenoids for such valves are provided. Also provided are methods of assembling solenoid valves.