Two-Stage Hydraulic Valve Structure for High Flow at Low Power
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Solution Overview
Problem
Existing hydraulic valves consume high power while providing a limited flow volume, necessitating a solution that reduces power consumption while increasing flow capacity.
Innovation Solution
A solenoid valve structure with a two-stage poppet mechanism, comprising a pilot-poppet and a main-poppet, where the lift of the main-poppet is independent of the pilot-poppet, allowing increased flow rates with reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional solenoid valve structure is used, then the power consumption is reduced, but the flow capacity is limited
Solution Approach 1:
The valve is divided into two independent stages: a pilot stage with a small poppet and a main stage with a large poppet. The pilot solenoid valve controls a small amount of fluid to modulate the main valve, separating the control function from the main flow control function. This segmentation allows the small solenoid to control a much larger flow through the main valve, increasing flow capacity while maintaining low power consumption.
Solution Approach 2:
The pilot poppet acts as an intermediary between the solenoid and the main poppet. The solenoid controls the pilot poppet, which in turn controls the main poppet position and the main flow. This intermediary mechanism allows a small energy input at the pilot stage to produce a large flow effect at the main stage, resolving the contradiction between power consumption and flow capacity.
2Productivity
If the main-poppet lift is dependent on the pilot-poppet, then the device complexity is reduced, but the flow rate is limited
Solution Approach 1:
The valve structure is segmented into two independent control stages. The main-poppet lift is made independent of the pilot-poppet position through separate control mechanisms. The pilot poppet controls pilot pressure, while the main poppet responds to both pilot pressure and main pressure differential, allowing independent optimization of each stage for maximum flow rate without increasing overall structural complexity.
Solution Approach 2:
The control mechanism transitions from a single-dimensional dependent lift to a two-dimensional independent control system. The main-poppet lift is controlled by both pilot pressure (from the pilot stage) and main pressure differential (from the main stage), adding another dimension of control independence. This allows the main poppet to achieve full lift for maximum flow rate regardless of the pilot-poppet position, increasing productivity without excessive complexity.
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 solution achieves a flow rate increase of up to 1.5 times higher than conventional solenoid valves at a given pressure drop, with power consumption reduced to less than 15 watts, enhancing efficiency and reducing energy consumption.
Implementation Method 1
Solenoids are widely used to convert electrical energy into mechanical movement
Data Source
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AI summary
The present disclosure relates to a hydraulic valve that has a two-stage construction that provides for higher fluid flow and lower power consumption. The present disclosure also relates to a hydraulic valve that may be constructed to include a pilot-poppet, a pilot- poppet valve seat, and a main-poppet. The main-poppet may be mechanically isolated from the pilot-poppet by the pilot-poppet valve seat.