Right-Angle Proportional Valve with Integrated Pilot Spool
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Solution Overview
Problem
Conventional hydraulic valves are large, energy-intensive, and costly due to the need for multiple pilot valves, which limits their application in space-constrained environments and increases component count and assembly complexity.
Innovation Solution
A valve design featuring a control spool with a tapered outer surface and integral feedback follower, combined with a proportional and on/off actuator, which reduces the need for separate pistons and pilot valves, allowing for efficient fluid metering and directional control with a single centering spring, thereby minimizing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple pilot valves are used to control the spool, then the valve can achieve precise control of hydraulic actuators, but the valve size, cost, and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple pilot valve functions into a single integrated pilot valve assembly. The pilot spool integrates proportional and on/off control functions, eliminating the need for separate pilot valves. The pilot spool is positioned within the main valve body and works cooperatively with the main spool, reducing component count while maintaining precise control capability through integrated fluid communication pathways.
Solution Approach 2:
The pilot spool serves multiple functions: it provides both proportional metering control and on/off directional control for the main spool. The single pilot valve assembly can selectively communicate pressurized pilot fluid to different ends of the main spool, enabling versatile control modes (proportional, on/off, bidirectional) without requiring multiple specialized pilot valves.
2Measurement precision
If multiple pilot valves are used to control the spool, then the valve can achieve precise control of hydraulic actuators, but the valve length and space requirements increase
Solution Approach 1:
The pilot spool is positioned within the main valve body in a compact arrangement, with the pilot spool axis perpendicular to the main spool axis. This three-dimensional integration allows the pilot valve assembly to occupy minimal space within the existing valve footprint, eliminating the need for extended valve length that would result from separate pilot valves.
Solution Approach 2:
The patent employs a right-angle configuration where the pilot spool axis is perpendicular to the main spool axis. This spatial arrangement allows the pilot control mechanism to operate in a different dimension, compacting the overall valve structure and reducing length requirements while maintaining full control functionality.
3Adaptability or versatility
If conventional metering valves are used with separate pistons and multiple pilot valves, then control functionality is achieved, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
The main spool and pilot spool are integrated into a single valve assembly with unified fluid communication pathways. The pilot spool is positioned within the main valve body and shares common fluid passages, eliminating the need for separate piston assemblies and multiple pilot valves. This integration reduces part count, simplifies manufacturing, and eases assembly while maintaining full control functionality.
Solution Approach 2:
The integrated valve assembly provides multiple control modes (proportional metering, on/off directional control, bidirectional flow control) through a single unified structure. The pilot spool can selectively control the main spool in various positions and configurations, delivering versatile control functionality without requiring multiple specialized components that would complicate manufacturing and assembly.
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 design achieves high-performance control of hydraulic actuators with reduced component count, cost, and length, while providing effective force feedback, making it suitable for space-constrained applications.
Implementation Method 1
a pressure differential across the actuators corresponds to a force of the actuators
Implementation Method 2
the pressure of the fluid acts on hydraulic surfaces of the chambers to affect movement of the actuators
Implementation Method 3
A feedback pin rides on ramped surfaces of the piston and provides force feedback to the first electrohydraulic actuator
Data Source
AI summary
A valve is disclosed for use with a hydraulic circuit. The valve may have a valve block, a central bore formed in the valve block, an actuator passage formed in the valve block and intersecting with the central bore, and at least one of a supply and a drain passage. The valve may also have a control spool movable to selectively connect the actuator passage and the at least one of the supply passage and the drain passage. The control spool may have a base end, and a tip end with a tapered outer surface. The valve may also have a first actuator configured to selectively meter a flow of pilot fluid and having a feedback follower configured to ride along the tapered outer surface of the control spool, and a second actuator configured to selectively direct the pilot fluid to the base and tip ends of the control spool.