Valve Cover Segmentation for Hydraulic Logic Control
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Solution Overview
Problem
Conventional active logic valves face challenges in cost-effective production and high variability due to complex control covers and the need for multiple components, leading to increased manufacturing costs and logistical complexities.
Innovation Solution
A valve design with an axially divided cover into an intermediate and functional cover, allowing for cost-effective manufacturing and a high number of variants with reduced logistical outlay, where the intermediate cover forms a standardized intersection for valve bushing and functional cover, enabling efficient assembly and reduced component variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the control cover is designed with multiple channels for two-stage or three-stage logic valves, then the hydraulic functionality is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The control cover is divided into two separate components: a first control cover and a second control cover. Each cover handles different functions, with the first cover managing pilot control valve arrangements and the second cover managing actuating pressure spaces. This segmentation reduces the channel complexity in each individual cover, making them easier and more cost-effective to manufacture while maintaining the overall hydraulic functionality of the two-stage or three-stage logic valve.
2Stability of the object's composition
If the valve bushing is extended into the control cover to receive the full extent of the valve piston, then the structural stability is improved, but the available control cross sections and maximum nominal volumetric flow are reduced
Solution Approach 1:
Instead of extending the valve bushing axially into the control cover (one-dimensional solution), the invention uses a radially extending annular flange on the valve bushing that engages with a corresponding recess in the first control cover. This radial engagement provides structural stability and positioning without reducing the axial control cross sections, thereby maintaining the maximum nominal volumetric flow capability of the valve.
3Ease of operation
If the control cover and valve bushing are provided as separate components with multiple channels, then the assembly flexibility is improved, but the production cost increases due to disproportionately expensive manufacturing
Solution Approach 1:
The control cover is segmented into two separate covers, each with simpler channel configurations that are easier and less expensive to manufacture. The first control cover contains channels for pilot control valve arrangements, while the second control cover contains channels for actuating pressure spaces. This segmentation maintains assembly flexibility while reducing the manufacturing complexity and cost of each individual component.
4Adaptability or versatility
If functional variants are provided by changing individual components, then the adaptability is improved, but the production outlay increases since each component would have to be changed
Solution Approach 1:
The two-control-cover design creates a modular system where the first and second control covers can be combined in different configurations to create various functional variants. The standardized interface between the valve bushing and the control covers allows different pilot control valve arrangements and actuating pressure space configurations to be assembled from the same basic components, reducing production outlay while maintaining high adaptability for different hydraulic functions.
Data Source
AI summary
A valve for installation in a valve bore of a housing or valve block includes a valve bushing for insertion into the valve bore, a guided valve piston that can be moved axially in the valve bushing, an activation section of said piston projecting above the valve bushing axially, and a valve cover that is configured to be arranged over the valve bore and that forms, together with the activation section of the valve piston, at least one activation pressure chamber.