Pilot-Actuated Hydrogen Shut-Off Valve With Smaller Solenoid Coil
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Solution Overview
Problem
Existing solenoid valves for hydrogen tank systems require larger magnetic coils due to weakened magnetic fields in axial air gaps, leading to increased energy consumption and installation space requirements.
Innovation Solution
A shut-off valve design utilizing a pilot valve system with a control valve armature and a main valve piston, where the control valve is indirectly actuated by a smaller solenoid coil, combining pneumatic and magnetic forces to open the main valve, reducing the magnetic force requirement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a solenoid coil acts directly on the main valve piston through a radial air gap, then the magnetic field is weakened in the axial air gap, but a larger solenoid coil is required, increasing energy consumption and installation space
Solution Approach 1:
The valve system is divided into two independent valve elements: a control valve element and a main valve element. The solenoid coil only needs to actuate the smaller control valve element, while the main valve element is actuated by a combination of magnetic force and pneumatic force. This segmentation allows the solenoid coil to be smaller and consume less energy.
Solution Approach 2:
A control valve element is introduced as an intermediary between the solenoid coil and the main valve piston. When the solenoid coil actuates the control valve element, it opens a control passage that allows pneumatic force to act on the main valve piston, combining pneumatic and magnetic forces to open the main valve without requiring a large solenoid coil.
2Reliability
If a plunger armature design is used with radial and axial air gaps, then field coupling via the radial air gap weakens the magnetic field in the axial air gap, but a larger solenoid coil is needed
Solution Approach 1:
The valve system separates the control function from the main valve actuation. The control valve element with its own armature handles the magnetic actuation, while the main valve element uses pneumatic assistance. This allows reliable operation with a smaller overall magnetic system and reduced installation space.
Solution Approach 2:
Pneumatic force is introduced to assist in opening the main valve element. When the control valve opens, pressurized gas flows through the control passage to the bottom surface of the main valve piston, creating an upward pneumatic force that combines with the magnetic force to reliably open the main valve without requiring a large solenoid coil.
3Volume of moving object
If indirect control via a control valve is implemented, then a smaller solenoid coil can be used, but the device complexity increases
Solution Approach 1:
The control valve element and main valve element are merged into a single integrated valve body with shared components such as the armature, magnetic circuit, and sealing structures. This integration reduces the overall complexity of the system despite the indirect control mechanism, as the two valve elements work together within a unified 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
This design allows for the use of a smaller solenoid coil, resulting in energy and space savings while ensuring reliable valve operation, even at varying operating conditions.
Implementation Method 1
an annular solenoid coil for actuating the control valve and for acting upon an end section of the main valve piston designed as a plunger armature
Implementation Method 2
The magnetic force generated in the axial air gap lifts the magnetic armature, or the valve element, out of the sealing seat against the spring force
Implementation Method 3
acted upon in the direction of the main valve seat by the spring force of a spring
Implementation Method 4
combining pneumatic and magnetic forces to open the main valve
Data Source
Figure 1a~1c
Figure 1d~1e
Figure 2a~2c
AI summary
The invention relates to a shut-off valve (1) for hydrogen tank systems, comprising: a main valve (2) having a main valve piston (3) which can be liftably moved, delimits a control chamber (6) at one end, interacts with a main valve seat (4) at the other end and is acted upon by the spring force of a spring (5) in the direction of the main valve seat (4); a control valve (7) for controlling the lifting movements of the main valve piston (3), wherein the control valve (7) has a control valve plunger (8) which is arranged at an axial distance coaxially from the main valve piston (3) and is acted upon by the spring force of the spring (5) or a further spring (9) in the direction of a control valve seat (10); and an annular solenoid coil (11) for actuating the control valve (7) and for acting on an end portion (12) of the main valve piston (3) designed as a solenoid plunger. The invention also relates to a hydrogen tank system comprising a shut-off valve (1) according to the invention.