Piloted Flow Diverter Valve Spool Design
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Solution Overview
Problem
Existing flow diverter valves are bulky, expensive, and structurally complex due to the need for high-power solenoid valves or complex piloting systems to manage high operating fluid pressures and flow rates, which increases overall dimensions and costs.
Innovation Solution
A flow diverter valve with an electromagnetically driven two-way and two-position piloting valve and a spool design that utilizes a pressure drop mechanism and elastic means to efficiently switch fluid flow between actuators, reducing the need for high-power components and simplifying the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high-power solenoid valve is used to move the spool against high hydraulic resistance, then the valve can handle high flow rates and pressures, but the valve becomes bulky and expensive
Solution Approach 1:
The patent introduces a piloting fluid as an intermediary substance that acts on the spool to move it between positions. This piloting fluid, supplied at controlled pressure through a piloting orifice, serves as a mediator that translates electromagnetic valve activation into mechanical spool movement without requiring the electromagnetic valve to directly overcome the full hydraulic resistance of the main fluid flow.
Solution Approach 2:
The patent replaces the direct mechanical/electromagnetic force application system with a fluid-based piloting system. Instead of using a high-power solenoid to directly move the spool against high pressure, the system uses a low-power electromagnetic valve to control piloting fluid pressure, which then mechanically moves the spool. This substitution of mechanical direct action with fluid-mediated action reduces the power and size requirements.
2Volume of stationary object
If a piloting system with elastic element is used to move the spool, then the solenoid valve size is reduced, but the valve structure becomes more complex
Solution Approach 1:
The patent extracts the elastic element (spring) from the direct spool actuation mechanism and replaces it with a piloting fluid pressure system. The spring is completely removed from the spool assembly, and its function of returning the spool to initial position is achieved through pressure differential control via the piloting orifice and piloting chamber, simplifying the mechanical structure.
Solution Approach 2:
The patent substitutes the mechanical spring-based return mechanism with a fluid pressure-based control system. The piloting fluid pressure differential, controlled through the piloting orifice and chamber, replaces the mechanical spring force for spool positioning, reducing mechanical complexity while maintaining functionality.
3Force
If high piloting fluid pressure is used to move the spool against high operating pressures, then the spool can be moved effectively, but the piloting system requires more complex components
Solution Approach 1:
The patent changes the pressure parameter distribution within the piloting system by introducing a restricted piloting orifice. This orifice creates a controlled pressure differential between the piloting chamber and the discharge side, allowing effective spool movement forces to be generated from a relatively low-pressure piloting fluid source, thereby avoiding the need for high-pressure piloting systems.
Solution Approach 2:
The patent applies local quality by creating a specific pressure condition only in the piloting chamber through the restricted orifice. The high pressure is localized only where needed for spool actuation, while the rest of the system operates at lower pressures, reducing the complexity requirements for pressure-containing components throughout the entire system.
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 solution enables a compact, reliable, and cost-effective flow diverter valve that efficiently switches high-pressure and high-flow-rate fluids between actuators, reducing the complexity and cost of the valve while maintaining performance.
Implementation Method 1
a flow diverter valve with an electromagnetically driven two-way and two-position piloting valve
Implementation Method 2
a spool design that utilizes a pressure drop mechanism
Implementation Method 3
and elastic means to efficiently switch fluid flow between actuators
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A flow diverter valve (1) comprises: an inlet port (P1) and a discharge port (P2), configured for being respectively connected to supplying means and to collecting means of an operating fluid; at least two pairs of ports (C1, C4; C2, C3) intended for being connected to respective actuators (10, 20), in which only one pair of ports at a time is flowingly connected to said inlet port (P1) and said discharge port (P2); a spool (2), in which a plurality of passages (3) are made that are arranged for being traversed by the operating fluid and configured for placing in communication said inlet (P1) and discharge (P2) ports alternatively with the one or the other pair of ports of said at least two pairs of ports (C1, C4; C2, C3), said plurality of passages (3) comprising a main conduit (30) arranged for leading the operating fluid at least into a first chamber (4) and into a second chamber (5), in which a first end (6) of said spool (2) faces said first chamber (4) and a second end (7) of said spool (2), opposite said first end (6), faces said second chamber (5); piloting means (8) that can be selectively activated for moving said spool (2). The aforesaid valve is characterised in that said first end (6) has a first frontal area (A1), exposed to a first thrust force (F1) of the operating fluid present in said first chamber (4), which is greater than a second frontal area (A2) of said second end (7), exposed to a second thrust force (F2) of the operating fluid present in said second chamber (5), so that when said piloting means (8) is not active, said spool (2) moves towards said second chamber (5).