Proportional Pressure Valve Differential Piston Positioning
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Solution Overview
Problem
Proportional pressure control valves in mobile machines experience irregular and abrupt starting behavior when using smaller, cheaper magnets with a shortened linear force stroke range, leading to undesirable 'jerky' and delayed machine startup.
Innovation Solution
A proportional pressure control valve design where the control piston is spaced apart from the intermediate element in a third position, allowing differential pressure to move the control piston and increase the fluid outflow to the tank connection, enabling a rapid discharge function for hydraulic consumers like clutches, using the differential fluid pressure to overcome the restoring force and achieve a larger opening cross section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If smaller, less expensive magnets with shortened linear force stroke range are used, then cost is reduced, but abrupt starting behavior and jerky machine startup occur
Solution Approach 1:
The control piston is pre-positioned at a third position spaced away from the intermediate element before actuation. This preliminary positioning creates initial flow cross-section for the first fluid connection, allowing smaller magnets to operate effectively without encountering large spring forces during startup, thereby eliminating abrupt starting behavior while using cost-effective actuators
Solution Approach 2:
The control piston acts as an intermediary between the magnet and the fluid connections. By positioning it away from the intermediate element, it mediates the force transmission in a way that avoids sudden force application, enabling smooth startup with smaller magnets while maintaining effective control over the fluid connections
2Area of stationary object
If the control piston is positioned closer to the intermediate element, then the opening cross-section is maximized, but larger magnets with longer stroke are required
Solution Approach 1:
The control piston is pre-positioned at a third position that provides sufficient opening cross-section for the first fluid connection before actuation begins. This preliminary configuration eliminates the need for large magnet strokes while maintaining adequate flow area, as the piston starts from a position that already provides necessary fluid passage
3Ease of operation
If larger magnets with longer linear force stroke range are used, then smooth operation is achieved, but cost increases
Solution Approach 1:
By pre-positioning the control piston at a third position spaced from the intermediate element, the system achieves smooth operation characteristics without requiring expensive large-stroke magnets. The preliminary positioning ensures gradual force application and smooth startup, eliminating the need for costly oversized actuators
Solution Approach 2:
The control piston configured at a spaced position acts as an intermediary that smooths force transmission from smaller magnets to the fluid system. This intermediary positioning enables smooth operation with cost-effective smaller magnets by avoiding direct engagement with the intermediate element
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 design allows the use of cheaper magnets with lower linear stroke range without abrupt starting issues, ensuring smooth machine startup by utilizing differential pressure to enhance the control piston's movement and fluid discharge, thus eliminating irregularities in the P-I characteristic.
Implementation Method 1
the regulating piston, upon release of the first fluid connection, can be moved from the first position to at least a third position by the total differential pressure generated by the flow of fluid
Implementation Method 2
If these large and comparatively expensive magnets were replaced with smaller, less expensive ones as actuators with the same force, the linear force-stroke range would have to be correspondingly shortened
Data Source
Figure 1~3
AI summary
The invention relates to a proportional pressure-regulating valve (10) for actuating a first fluid connection (f1) from a working connection (A) to a tank connection (T) and a second fluid connection (f2) from a supply connection (P) to the working connection (A), comprising a regulating piston (14), which is guided in a displaceable manner in a valve housing (12) and opens the first fluid connection (f1) and closes the second fluid connection (f2) when in at least one first position, and closes the first fluid connection (f1) and opens the second fluid connection (f2) when in at least one second position, is characterised in that the regulating piston (14) can be displaced from a first position into a third position when the first fluid connection (f1) is open by the total differential pressure produced when fluid flows through, and that when the regulating piston (14) is in the third position, the first fluid connection (f1) is opened with an enlarged opening cross section compared to the first position and the second fluid connection (f2) remains closed.