Sheet-Metal Flapper-Nozzle Assembly for Low-Leakage Servo Valves
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Solution Overview
Problem
Conventional flapper-type servo valves are complex, bulky, and require precise manufacturing and calibration, leading to potential failures and increased costs due to numerous moving parts and complex assembly processes, while also being difficult to manufacture and assemble efficiently.
Innovation Solution
An integral flapper and nozzle structure formed by sheets of metal, where the flapper, orifices, and nozzles are created as a single component, allowing for precise positioning and movement to regulate fluid flow, reducing the number of parts and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional flapper-type servo valve systems are used, then fluid flow control functionality is achieved, but the system becomes complex, bulky, and difficult to manufacture with multiple moving parts and calibration requirements
Solution Approach 1:
The patent combines the flapper and nozzle into a single integral component made from a single piece of material. This merging eliminates the need for separate flapper and nozzle parts, reducing the number of moving parts and potential failure points while maintaining the fluid flow control functionality. The integral structure removes the need for calibration between separate components.
2Manufacturing precision
If conventional flapper-type servo valves with multiple separate parts are used, then fluid flow control is achieved, but manufacturing and assembly become time-consuming and expensive due to precise calibration requirements
Solution Approach 1:
By forming the flapper and nozzle as a single integral component from one piece of material, the patent eliminates the need for separate manufacturing and assembly of multiple parts. The single-component structure removes calibration requirements between separate flapper and nozzle assemblies, significantly simplifying manufacturing while maintaining precise fluid flow control.
3Volume of stationary object
If conventional flapper-type servo valves are used, then fluid flow management is achieved, but the system becomes bulky and large in size
Solution Approach 1:
The integral flapper-nozzle component reduces the overall system volume by eliminating separate parts and their associated mounting structures. The single-component design allows for more compact arrangement of the servo valve system while maintaining all necessary fluid flow control functions.
4Reliability
If conventional flapper-type servo valves with multiple separate parts and sealing elements are used, then fluid flow control is achieved, but leakage risks increase due to multiple sealing interfaces
Solution Approach 1:
By forming the flapper and nozzle as a single integral component, the patent eliminates the interface between separate flapper and nozzle parts where sealing would be required. The single-piece construction removes multiple sealing interfaces and associated O-rings or seals, thereby reducing leakage risks while maintaining fluid flow control functionality.
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 solution enables a compact, reliable, and responsive servo valve design that is simpler to manufacture and assemble, with improved precision and reduced leakage, capable of handling high fluid flows and frequencies with fewer complex parts.
Implementation Method 1
the flapper, orifices and nozzles are formed by sheets of metal formed into a single component... movement of the flapper relative to the nozzles to regulate fluid flow
Data Source
AI summary
An integral flapper and nozzle structure for a servo valve assembly whereby the flapper, orifices and nozzles are formed by sheets of metal formed into a single component.