Pilot-Poppet Hydraulic Valve for High Flow and Low Power
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Solution Overview
Problem
Existing hydraulic valves face challenges in reducing power consumption while maintaining high flow rates, particularly in off-road equipment applications where efficient energy use is crucial.
Innovation Solution
The hydraulic valve design incorporates a pilot-poppet and main-poppet mechanism with vertical and inclined drill holes, a solenoid assembly, and a valve cage to enhance flow capacity and reduce power consumption, featuring a two-stage construction that isolates the main-poppet from the pilot-poppet, allowing independent movement and increased fluid flow with reduced solenoid input power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional solenoid valve design is used, then power consumption is reduced, but flow rate is limited
Solution Approach 1:
The valve is divided into two independent stages: a pilot stage with a small poppet and a main stage with a large poppet. The pilot poppet (with 0.062 inch orifice) controls the main poppet (with 0.187 inch orifice) through a pilot port. This segmentation allows the small solenoid to control a much larger flow area indirectly, achieving high flow rates with low power consumption.
Solution Approach 2:
The pilot port acts as an intermediary between the solenoid and the main flow path. When the solenoid activates the pilot poppet, it opens the pilot port which then allows pilot pressure to act on the main poppet, causing it to open and allow main flow. This intermediary mechanism amplifies the control capability of the small solenoid.
2Quantity of substance
If larger orifice is used to increase flow rate, then flow capacity increases, but pressure drop increases
Solution Approach 1:
The flow control is segmented into two stages: pilot flow through the small orifice and main flow through the large orifice. The pilot stage creates minimal pressure drop while controlling the main stage, which handles the bulk flow with its larger area, thereby maintaining low overall pressure drop while achieving high flow capacity.
3Quantity of substance
If direct mechanical coupling between pilot-poppet and main-poppet is used, then control is simplified, but flow rate is limited by coupled movement
Solution Approach 1:
Instead of direct mechanical coupling, the patent uses fluid pressure as an intermediary. The pilot poppet controls pilot pressure, which then acts on the main poppet through the pilot port. This allows independent movement of the two poppets while maintaining control, enabling the main poppet to achieve full lift for maximum flow without being mechanically constrained by the pilot poppet's limited travel.
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 achieves a significant increase in flow rate, up to 50% higher than conventional solenoid valves, while maintaining low power consumption, with flow rates of 20 GPM at 100 psi pressure drop, effectively addressing the need for efficient energy use in off-road equipment.
Implementation Method 1
The solenoid coil may be arranged and configured to drive the pilot-poppet in a second axial direction toward the second position when energized
Implementation Method 2
The aid of fluid pressure may also help to lift the pilot-poppet and thereby reduce power consumption
Implementation Method 3
the main poppet chamber is pressurized from the side port through the chamber pressurization orifice such that spring force from the main-poppet spring combined with pressure within the main-poppet chamber cooperate to hold the main-poppet chamber in the closed position
Data Source
AI summary
The present disclosure relates to a hydraulic valve that has a two-stage con-struction that provides for higher fluid flow and lower power consumption. The present disclosure also relates to a hydraulic valve that may be constructed to include a pilot-poppet, a pilot-poppet valve seat, and a main-poppet. The main-poppet may be mechanically isolated from the pilot-poppet by the pilot-poppet valve seat.