Poppet Valve Thermally Sprayed Non-Magnetic Layer
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Solution Overview
Problem
Aging and damage to the non-magnetic plate member in poppet valves, such as wear and settling, cause response delays and juddering due to increased separation resistance and potential fragment entry between the poppet and valve casing, which existing diagnosis systems fail to prevent effectively.
Innovation Solution
A poppet valve configuration featuring a thermally sprayed layer with non-magnetic material on the poppet or valve casing end surfaces, where the Vickers hardness of the layer is between 50Hv less than and 100Hv greater than the base surface hardness, and a biasing member to counteract magnetic attraction, along with an uneven surface to reduce pressure differentials, enhancing responsiveness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a non-magnetic plate member is disposed between the poppet and valve casing, then response delay is improved, but wear and settling of the plate member occurs causing aging
Solution Approach 1:
A thermally sprayed layer of non-magnetic material is applied to the valve casing surface to serve as an intermediary between the magnetic poppet and the magnetic valve casing. This layer prevents direct magnetic attraction and contact while maintaining the non-magnetic separation function, eliminating wear and settling issues of separate plate members.
Solution Approach 2:
The mechanical plate member structure is replaced by a thermally sprayed coating layer. Instead of using a separate mechanical component that can wear and settle, the invention uses a deposited material layer that is integrated with the valve casing surface, eliminating mechanical wear between discrete parts.
2Device complexity
If the poppet and valve casing make direct contact, then structural simplicity is maintained, but magnetic attraction causes response delay
Solution Approach 1:
The thermally sprayed non-magnetic material layer acts as an intermediary between the magnetic poppet and magnetic valve casing, preventing direct magnetic attraction while maintaining a simple integrated structure without separate mechanical components.
Solution Approach 2:
The valve casing surface is created as a composite structure with a base material and a thermally sprayed non-magnetic material layer, combining magnetic and non-magnetic properties in a single integrated component to prevent magnetic attraction.
3Strength
If high hardness material is used for the contact surface, then wear resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The surface hardness of the valve casing is changed by applying a thermally sprayed material layer with specific hardness properties. This allows achieving high wear resistance through material selection and deposition parameters rather than complex heat treatment or alloying processes.
Solution Approach 2:
A composite structure is created by depositing a thermally sprayed material layer on the valve casing base material. This combines the structural properties of the base material with the wear-resistant properties of the sprayed layer, achieving high hardness without complicating the base manufacturing process.
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 effectively suppresses response delays and juddering by maintaining the thermally sprayed layer's strength and reducing magnetic attraction, improving the poppet valve's responsiveness and reliability in hydraulic machines and renewable-energy power generating systems.
Implementation Method 1
Aging and damage to the non-magnetic plate member in poppet valves, such as wear and settling, cause response delays and juddering due to increased separation resistance and potential fragment entry between the poppet and valve casing
Implementation Method 2
a thermally sprayed layer including a non-magnetic material, formed on at least a part of an end surface of the poppet (58) or a contact surface (62a) of the first valve casing (62)
Data Source
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AI summary
A poppet valve includes: a valve seat (56); a poppet (58) disposed so as to face the valve seat; an actuator (60) for driving the poppet; a first valve casing (62) which houses the actuator and which includes a contact surface (62a) capable of making contact with an end surface of the poppet opposite to the valve seat; and a thermally sprayed layer (64) including a non-magnetic material, formed on at least a part of the end surface of the poppet or the contact surface of the first valve casing. A Vickers hardness Hv1 of the end surface of the poppet or the contact surface of the first valve casing and a Vickers hardness Hv2 of the thermally sprayed layer satisfy a relationship (Hv1-50Hv)≤Hv2≤(Hv1+100Hv).