Pre-tensioning Pre-twisting 2D Electro-hydraulic Valve
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Solution Overview
Problem
Existing electro-hydraulic proportional valves are susceptible to friction force, hydrodynamic force, and oil liquid pollution, leading to clamping stagnation and increased leakage flow, which limits their performance under high pressure and large flow conditions.
Innovation Solution
A pre-tensioning-pre-twisting full-bridge 2D electro-hydraulic proportional directional valve is designed with a compression-torsion coupling mechanism and linear electro-mechanical converters, allowing for a twisting motion of the valve core that minimizes friction and hydrodynamic forces, enabling proportional control at zero pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a direct-acting proportional valve uses a slide valve structure to balance axial static pressure, then the valve can control position of the valve core, but it is easily affected by friction force or oil liquid pollution, causing clamping stagnation
Solution Approach 1:
The valve core is divided into multiple segments that can move relative to each other, transforming the single sliding surface into multiple smaller sliding surfaces. This segmentation reduces the contact area and friction force on each surface, preventing clamping stagnation while maintaining positioning accuracy through coordinated segment movement
Solution Approach 2:
The valve core structure transitions from a single-dimensional sliding motion to a multi-dimensional configuration with segments that can move independently in different directions. This dimensional change allows the valve to maintain positioning accuracy while reducing frictional constraints through enhanced movement freedom
2Ease of manufacture
If a proportional electromagnet is used to drive the valve core, then the structure is simple and reliable with good manufacturability, but the magnetic saturation limit restricts the output force, unable to fundamentally solve the problem of impact of hydrodynamic force under high pressure and large flow
Solution Approach 1:
The valve core segments are pre-positioned and pre-loaded to optimize their initial contact surfaces and force distribution. This preliminary configuration ensures that when the electromagnet activates, the force is efficiently transmitted through pre-aligned segments, maximizing the limited electromagnetic force output while maintaining structural simplicity
Solution Approach 2:
The segmented valve core structure acts as an intermediary mechanism between the proportional electromagnet and the hydraulic fluid. The segments amplify and distribute the limited electromagnetic force more effectively, overcoming hydrodynamic forces under high pressure and large flow conditions while preserving the simplicity of the electromagnet design
3Productivity
If a guiding and control stage is used to eliminate the impact of hydrodynamic force, then the flow capacity is improved, but the guiding and controlling oil path loses pressure, causing the whole valve to be unable to work normally
Solution Approach 1:
The guiding and control function is extracted from a separate oil path and integrated directly into the valve core segments. This eliminates the need for a dedicated guiding oil path, thereby removing the source of pressure loss while maintaining the ability to control hydrodynamic forces and preserve high flow capacity
4Reliability
If the valve core is designed to rotate and axially slide inside the valve body, then the compression-torsion coupling converts linear motion to twisting motion minimizing friction, but the structure becomes more complex
Solution Approach 1:
The rotation and axial sliding functions are merged into a single integrated valve core structure. The segmented design allows both motions to occur simultaneously within one component rather than requiring separate mechanisms, reducing overall structural complexity while maintaining the friction-minimizing twisting motion benefits
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 enhances the driving force applied by the proportional electromagnet, improves axial positioning accuracy, and maintains high flow and pressure capabilities, effectively overcoming nonlinear factors like friction and hydrodynamic forces, while maintaining a simple structure.
Implementation Method 1
A pre-tensioning-pre-twisting full-bridge 2D electro-hydraulic proportional directional valve is designed with a compression-torsion coupling mechanism and linear electro-mechanical converters, allowing for a twisting motion of the valve core that minimizes friction and hydrodynamic forces
Implementation Method 2
The solution enhances the driving force applied by the proportional electromagnet, improves axial positioning accuracy, and maintains high flow and pressure capabilities
Data Source
AI summary
A pre-tensioning-pre-twisting full-bridge 2D electro-hydraulic proportional directional valve can include a 2D valve, linear electro-mechanical converters at two ends of the 2D valve, and a compression-torsion coupling between the linear electro-mechanical converters. The 2D valve can include a valve core and a valve body, wherein the valve core is rotatably and axially slidably disposed inside an inner hole that is set along the axis line of the valve body. Each end shoulder of the valve core is provided with a pair of high pressure holes and low pressure holes, which are respectively communicated with a P opening and a T opening through an inner hole of the valve core.