Spool Valve Pilot Fluid Control for Air-Jet Looms
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Solution Overview
Problem
Conventional spool valves used in air-jet looms require large solenoid coils and high power consumption to manage high flow rates, and they lack control over discharge flow rate and pressure.
Innovation Solution
A spool valve design utilizing a pilot fluid to displace the spool axially, with a spring bias and a pilot valve mechanism to control flow rate and pressure, eliminating the need for a large solenoid coil and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a solenoid type spool valve is used to control high flow rate pressure fluid, then the flow rate control capability is improved, but the solenoid coil size increases and power consumption increases
Solution Approach 1:
The patent introduces a pilot fluid as an intermediary to control the spool displacement. Instead of using a large solenoid coil to directly move the spool against high pressure fluid, a small amount of pilot fluid is used to generate pilot pressure that acts on the spool's end surface. This pilot pressure mechanism enables indirect control of the main spool, achieving high flow rate control with minimal power consumption.
2Productivity
If a large solenoid coil is used to move the spool against high pressure fluid, then the flow rate control is achieved, but the valve size increases
Solution Approach 1:
The pilot fluid serves as a mediator that transmits control force to the spool. The pilot pressure, generated by a small pilot orifice, acts on the large end surface area of the spool to produce sufficient displacement force. This eliminates the need for a large solenoid coil, thereby reducing the overall valve size while maintaining flow rate control capability.
Solution Approach 2:
The patent changes the control parameter from direct electromagnetic force (solenoid current) to fluid pressure (pilot pressure). By controlling the pilot fluid pressure through a small orifice, the spool position is controlled indirectly. This parameter transformation enables compact valve design since the control mechanism size is determined by the small pilot orifice rather than a large solenoid coil.
3Ease of operation
If a piston is added to receive pilot fluid pressure and connect to the spool, then the spool displacement control is improved, but the device complexity increases
Solution Approach 1:
The patent merges the pilot pressure receiving function directly into the spool structure by providing a pilot pressure receiving chamber formed in the spool itself. The pilot fluid pressure is introduced directly into this chamber, which is in communication with the spool's end surface. This integration eliminates the need for a separate piston component, reducing structural complexity while maintaining effective spool displacement control.
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 spool valve achieves efficient control over discharge flow rate and pressure, reduces size, and enhances responsiveness and compactness, while minimizing power consumption, even with high flow rates.
Implementation Method 1
a pilot valve mechanism disposed in the valve body and which causes displacement of the spool along an axial direction under the pressure of a pilot fluid that acts on one end surface of the spool
Implementation Method 2
a spring that biases the spool toward one side in the axial direction
Data Source
AI summary
A spool valve is equipped with a valve body, a spool arranged in a valve chamber such that the spool can be displaced between a first position, which allows communication between an inlet port and an outlet port, and a second position, which blocks communication between the inlet port and the outlet port, a pilot valve mechanism disposed in the valve body and which causes displacement of the spool along an axial direction under the pressure of a pilot fluid that acts on one end surface of the spool, and a spring that biases the spool toward one side in the axial direction.