Pneumatic-Hydraulic Valve Assembly for Compact Pressure Conversion
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Solution Overview
Problem
Existing 'air over hydraulic' systems require large, complex, and expensive pressure converters to convert pneumatic pressure into hydraulic pressure, which are not feasible for all vehicles due to space constraints.
Innovation Solution
A valve assembly that uses pneumatic pressure as control pressure to actuate a hydraulic valve through a simply constructed control piston, transmitting pressure via a tappet to a spring plate system, allowing for a 10:1 pressure ratio without the need for extensive pressure conversion, enabling compact and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a pressure converter is used to convert pneumatic pressure into hydraulic pressure, then the desired pressure conversion is achieved, but the device becomes large, complex, and expensive
Solution Approach 1:
The valve assembly is divided into a pneumatic part and a hydraulic part that are functionally separated but integrated in one component. The pneumatic part receives control pressure and transmits it through a control piston and tappet to actuate the hydraulic valve, while the hydraulic part contains the slide valve and spring mechanism. This segmentation allows each part to be optimized independently while maintaining compact integration.
Solution Approach 2:
The patent combines the pneumatic control function and hydraulic valve actuation function into a single integrated valve assembly. The housing contains both pneumatic connections (for control pressure) and hydraulic connections (for working fluid), with the control piston mechanically linked to the hydraulic slide through a tappet and spring mechanism. This merging eliminates the need for separate pressure converters while achieving the desired pressure multiplication effect.
2Power
If a pressure converter is used to convert pneumatic pressure into hydraulic pressure, then the desired pressure conversion is achieved, but the device occupies large space
Solution Approach 1:
The control piston is positioned within the housing in such a way that it shares space with the hydraulic components. The tappet mechanism is nested within the housing structure, and the spring is contained within the same volume. This nested arrangement allows multiple functional elements to occupy overlapping spatial zones, significantly reducing the overall device volume compared to a conventional pressure converter.
3Power
If a pressure converter is used to convert pneumatic pressure into hydraulic pressure, then the desired pressure conversion is achieved, but the manufacturing cost increases
Solution Approach 1:
Different parts of the valve assembly have different functional requirements, and the design optimizes each local region accordingly. The pneumatic part has larger bore dimensions to accommodate control pressure, while the hydraulic part has precisely fitted sliding surfaces for the slide valve. The spring and tappet mechanisms are designed with specific geometric features for force transmission. This localized optimization allows standard manufacturing processes to be applied to each region, reducing overall manufacturing complexity and cost.
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
Enables efficient conversion of pneumatic pressure to hydraulic pressure in a compact and cost-effective manner, suitable for vehicle brake systems, eliminating the need for large pressure converters and allowing for integrated pneumatic-hydraulic control systems.
Implementation Method 1
pneumatic pressure can be converted into hydraulic outlet pressure in a simple manner
Implementation Method 2
The control piston transmits the pressure acting on it via a tappet to a first spring plate
Implementation Method 3
a helical compression spring is arranged in an axial cylinder bore of the housing half of the hydraulic part
Data Source
Figure 1~2
Figure 3
AI summary
The valve assembly (1) has a valve housing (2) that is provided with two housing halves (3,4) which divide the valve assembly into a pneumatic portion (5) and a hydraulic portion (6). The pneumatic portion is formed as a control chamber and the hydraulic portion is formed as a working chamber. A valve used as a slider (24) is arranged in the hydraulic portion. A compressed air connection (10) acting on a compressed air control piston (12) arranged by pneumatic portion is operable. A hydraulic input terminal (7) is connected with a hydraulic output terminal (8) by actuating slider.