Variable Flow Valve Using Magnetic Plunger Actuation
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Solution Overview
Problem
Existing electromagnetic valves are not capable of operating as variable flow valves, limiting their ability to control fluid flow effectively.
Innovation Solution
A variable flow valve design incorporating a valve body assembly with a valve element and actuator guide, along with a plunger assembly and coil, allowing the valve element to move between positions to control fluid flow, utilizing magnetic fields to adjust the flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional electromagnetic valves are used, then the valve structure is simple and manufacturing cost is low, but the valve cannot operate as a variable flow valve and cannot control fluid flow effectively
Solution Approach 1:
The valve element is designed to be movable along the longitudinal axis between multiple positions (fully closed, partially open, fully open) rather than fixed in a single position. This dynamic positioning capability enables variable flow control while maintaining a relatively simple overall valve structure that builds upon conventional electromagnetic valve designs.
Solution Approach 2:
The electromagnetic valve is designed to perform multiple functions: it can operate as a variable flow valve for continuous flow control, as a two-way valve (fully open/closed), or as a three-way valve with a T-shaped flow path. This multi-functionality achieves adaptability without proportionally increasing structural complexity.
2Adaptability or versatility
If the valve element is made movable to enable variable flow control, then flow control capability is improved, but the sealing reliability may deteriorate
Solution Approach 1:
The plunger assembly replaces traditional mechanical sealing mechanisms with a magnetic field-based holding system. The coil generates a magnetic field that holds the armature (and attached plunger) in position, eliminating the need for complex mechanical springs or tensioning mechanisms that could compromise sealing reliability while enabling smooth variable flow control.
Solution Approach 2:
The valve element position is controlled by varying the magnetic field strength through adjustable current to the coil. By changing the electrical parameter (current), the valve element can be positioned precisely at any point between fully closed and fully open, maintaining reliable sealing through magnetic holding force while enabling continuous variable flow control.
3Measurement precision
If a magnetic field is used to move the valve element, then precise flow control is achieved, but energy consumption increases
Solution Approach 1:
The electromagnetic coil operates in a periodic manner rather than continuously: it is energized only when valve element position adjustment is needed, and de-energized during steady-state operation. This periodic activation maintains precise flow control capability while significantly reducing overall energy consumption compared to continuous electromagnetic actuation.
Solution Approach 2:
The magnetic field system is designed to hold the valve element position without continuous energy input once positioned. The magnetic field generates sufficient holding force to maintain the valve element at the desired position, and the system uses minimal energy for position adjustments rather than continuous power consumption, achieving precise control with reduced energy use.
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
Enables precise control of fluid flow by varying the position and force applied to the valve element, offering intermediate flow rates and reduced construction complexity and cost, especially in low-pressure hydraulic circuits.
Implementation Method 1
The coil is disposed about the cover and is configured to generate a magnetic field to move the armature
Data Source
AI summary
A variable flow valve having an externally threaded valve body, a valve element and an actuator that includes coil and a plunger assembly. The coil can be operated to move the plunger assembly to drive the valve element into engagement with a seat surface on a valve seat in the valve body.