Solenoid Valve Return Spring for Adjustable Flow Rates
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Solution Overview
Problem
Existing solenoid valves lack the ability to adjust flow rates effectively, requiring separate valves for different applications like clutch control units and transmission brake units, and existing proportional valves are larger and consume more power.
Innovation Solution
A solenoid valve design featuring a return spring with varying spring constants, allowing for multiple partially open operating states and adjustable flow rates by utilizing a cylindrical coil spring with distinct regions, enabling current-controlled operation and replacing the need for multiple simple solenoid valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a simple solenoid valve is used, then the structure is simple and cost is low, but the flow rate cannot be adjusted and multiple valves are needed for different applications
Solution Approach 1:
The return spring is designed with variable spring constant along its length, creating different resistance zones that enable the valve to achieve multiple stable positions (fully closed, partially open, fully open) instead of just binary states. This dynamic spring structure allows continuous flow rate adjustment without requiring multiple separate valves.
Solution Approach 2:
The spring constant of the return spring is varied along its length with at least two different regions having different spring constants. This parameter change in the spring's mechanical property enables the valve to have multiple equilibrium positions, providing adjustable flow rates while maintaining a single valve structure.
2Ease of operation
If a proportional valve is used to achieve partially open states, then flow rate adjustment is possible, but the valve size is larger and power consumption is higher
Solution Approach 1:
The patent replaces the complex proportional control mechanism with a mechanically advantageous spring system. The variable spring constant creates natural equilibrium positions that require minimal holding force, reducing power consumption compared to traditional proportional valves while maintaining current-controlled operation capability.
Solution Approach 2:
The dynamic spring structure with varying spring constant creates multiple stable equilibrium positions that can be reached through current control. This allows the valve to maintain partially open states with minimal power consumption, as the mechanical spring structure provides inherent stability rather than requiring continuous high power input.
3Adaptability or versatility
If multiple solenoid valves are used for different flow rates, then different applications are covered, but the device complexity and cost increase
Solution Approach 1:
The single solenoid valve incorporates multiple flow rate capabilities through the variable spring constant design, allowing it to perform the functions of multiple separate valves. The valve can operate in fully closed, partially open, and fully open states, providing universal applicability for different flow rate requirements.
Solution Approach 2:
The patent combines the functionality of multiple solenoid valves into a single valve by integrating a return spring with at least two different spring constant regions. This merging of functions into one device reduces system complexity while maintaining the ability to serve different applications.
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 solenoid valve achieves adjustable flow rates and multiple partially open states with reduced power consumption and cost, addressing the limitations of existing designs by leveraging a return spring with different spring constants to control armature movement.
Implementation Method 1
an electromagnet with a coil and a core
Implementation Method 2
a return spring for the armature, the return spring having at least a first region with a first spring constant and a second region with a second spring constant
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a solenoid valve (1) comprising a housing (2), an electromagnet with a coil (3) and a core (6), an armature (4), and a return spring (5) for the armature (4), wherein the housing (2) has a valve inlet (10) and a valve outlet (11), and the armature (4) is displaceable within the housing (2) by energizing the coil (3) to open or close the solenoid valve. The return spring (5) has at least a first section (30) with a first spring constant (R1) and a second section (31) with a second spring constant (R2), wherein the spring constant (R2) of the second section (31) is greater than the spring constant (R1) of the first section (30).