Overrun-Air Recirculation Valve Geometry for Lower Closing Force
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Solution Overview
Problem
Overrun-air recirculation valves face challenges in achieving fast actuation times with low electromagnetic actuating forces, leading to large spring forces and increased installation space requirements, which complicates manufacturing and efficiency.
Innovation Solution
The design includes a control body with a radially outer circumferentially closed lateral surface and a radially inner axial flow-on surface, where the flow-off edge is offset relative to the bearing edge, directing airflow into the gap between the valve seat and bearing edge, reducing the closing force and allowing for a smaller electromagnet, thus optimizing force curves and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the opening stroke is shortened to achieve fast actuation times, then the electromagnetic actuating force can be reduced, but the static pressure falls very quickly causing large closing forces that require larger springs and electromagnets
Solution Approach 1:
The control body is divided into functionally distinct surfaces: a bearing edge for valve seat contact, a flow-on surface for pressure equalization, and a flow-off edge for controlled pressure release. This segmentation allows different regions to manage different aspects of the force balance, enabling fast actuation without excessive closing forces.
Solution Approach 2:
The flow-on surface is positioned radially inward and axially offset from the bearing edge, creating a localized region where pressure equalization occurs. The flow-off edge is specifically positioned to direct airflow at a controlled angle (≤15°) relative to the bearing edge, optimizing the local pressure distribution to reduce closing forces during fast opening.
2Reliability
If pressure compensation openings are brought directly up to the narrow opening area to transfer low static pressure, then pressure equalization improves, but relatively large spring forces and electromagnetic forces are required for closing and initiating opening
Solution Approach 1:
The flow-on surface is positioned in a different axial dimension relative to the bearing edge, creating a stepped configuration. This axial offset allows pressure equalization to occur at a different location than the valve seat contact, enabling effective pressure compensation without requiring large forces. The wall with openings extends radially inward from the circumferentially closed lateral surface, creating a three-dimensional pressure management 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
This configuration enables fast actuation times with reduced electromagnetic forces, minimizing the size of the solenoid and manufacturing costs, while maintaining high durability and tightness, by optimizing airflow direction and force-acting surfaces.
Implementation Method 1
the flow-off edge is offset in an axial direction relative to the circumferential bearing edge by a maximum amount so that a first vector which extends radially outwardly from the radially outer annular flow-off edge to a nearest point of the circumferential bearing edge to a plane which is spanned by the circumferential bearing edge encloses an angle of at most 15°
Implementation Method 2
Overrun-air recirculation valves are often electromagnetically actuated, wherein the control body of the valve is moved via the armature by the electromagnetic force
Implementation Method 3
only the force of a spring must be overcome for actuation
Data Source
AI summary
An overrun-air recirculation valve includes a flow housing having a flow channel, a valve seat, an actuator, an actuating member movable via the actuator, and a control body fastened to the actuating member. The control body has a lateral outer surface having a bearing edge which is placeable onto and liftable off of the valve seat, a flow-on surface arranged on an axial side facing away from the actuating member, and a wall extending radially inwardly from the lateral outer surface. The flow-on surface has a flow-off edge offset axially to the bearing edge so that a first vector extending radially outwardly from the flow-off edge to a nearest point of the bearing edge to a plane spanned by the bearing edge encloses an angle of <15°, and the wall is offset axially to the bearing edge and to the flow-off edge in a direction of the actuating member.