RU2800195C1 - Composite structure of digital electronically controlled proportional hydraulic valve - Google Patents

Abstract

FIELD: programming.

SUBSTANCE: claimed invention relates to the field of control and programming of changing/maintaining the functional parameters of the hydraulic system, including in automatic mode, due to digital control of the speed and direction of the hydraulic fluid flow with a given accuracy in all hydraulic circuits. The claimed device for a digital electronically controlled proportional hydraulic valve (DEPHV) includes a housing, and also comprises an interconnected digital hydraulic flow control module, a digital regulator control module, a stepper motor with a pusher on each channel, a microprocessor that controls the electric motor on each channel, a digital feedback unit on each channel, high-atmospheric and low-atmospheric parts are allocated in the body, whereas the high-atmospheric and low-atmospheric parts are joined in the same horizontal plane using a modular type of installation through O-rings, and to pass hydraulic flows of the same pressure between themselves, parts of the same type in sections are joined through vertical side planes, the control unit of the hydraulic valve with geometric programming of flow characteristics, which is a prefabricated block-regulator with a hollow rectangular spool for each channel and forms a high-atmospheric part, whereas for the parts of the high-atmospheric part, vertical planes for joining parts made of materials of the same type are provided, and for parts of the low-atmospheric part, horizontal planes for joining parts made of materials of different types are provided, whereas the regulation assembly consists of two hermetically pressed plates with throughput windows: a fixed distribution plate and a regulation plate that moves along the plate using an electromechanical drive controlled by a microcontroller on the base data of a digital feedback block, while the processes of pressure reduction in the cavities of the hydraulic cylinder are inversely proportional and synchronous, the regulation windows are located in one moving part.

EFFECT: providing a device for high-precision proportional dynamic control of the operation of the hydraulic motor, which allows for a reduction in the number of small and high-precision structural elements and the total number of parts, ensures the rejection of complex/expensive materials and processing technologies in the production of elements and parts of the DEPHV, reduces the proportion of parts from metal alloys up to a value of not more than 35% of the total volume of the product material and the use in the design of the hydraulic distributor of materials suitable for recycling and/or being a product of recycling, and also provides a method for reliable sealed joining of parts made of metal alloys and synthetic polymers.

1 cl, 11 dwg

Description

The claimed invention relates to the field of control and programming of changing/maintaining the functional parameters of the hydraulic system, including in automatic mode, due to digital control of the speed and direction of the hydraulic fluid flow with a given accuracy in all hydraulic circuits.

Various electrically controlled proportional valves (Danfoss, Duplomatic, Athos, Mug, etc.) and various digital control devices for hydraulic actuators are known from the prior art (for example, see patent RU 10469 U1, published on 11/16/1998). However, there are no direct analogues. The closest in terms of functional orientation and capabilities are traditionally manufactured hydraulic valves with cast iron, steel or aluminum housings. The housings of traditional hydraulic distributors carry a large number of hydraulic control channels, and are also housings for hydraulic control and hydraulic compensation parts.

The objective of the claimed invention is to eliminate the shortcomings of the prior art. The technical result consists in providing a device for high-precision proportional dynamic control of the operation of a hydraulic motor, which allows for a reduction in the number of small and high-precision structural elements and the total number of parts, ensures the rejection of complex / expensive materials and processing technologies in the production of elements and parts of the CEPGR, reduces the proportion of parts made of metal alloys to a value of not more than 35% of the total volume of the product material and uses materials suitable for recycling and / or being a product of recycling in the design of the hydraulic distributor, and also provides a method for reliable hermetic and joining parts made of metal alloys and synthetic polymers.

The problem is solved, and the claimed technical result is achieved by means of the claimed device of a digital electronically controlled proportional valve (CEPHR). The declared device of the digital electronically controlled proportional hydraulic distributor (CEPGR) includes the case, and also contains the interconnected digital control module of the hydraulic flow, the regulator digital control module, a step electric motor with a pusher on each channel, a microprocessor that controls each channel, a digital feedback unit on each channel, high-and-and-and-admies were excreted in the building high-and-and-and-admies. Fern and low -atmospheric parts, while the highly atmospheric and low -atmospheric part are joined in one horizontal plane using a modular type of installation through the sealing rings of a round section, and to pass the hydropoots of the same type of one type in sections, they are joined through vertical side planes, a regulatory unit of a hydraulic distributor with a “geometric programming” of expenditure characteristics a stick, which is a team block-regulator with a hollow rectangular spool for each channel and forms a high-atmospheric part, while the regulatory node consists of two hermetically pressed plates with accessories: a distributive plate of a motionless and regulatory plate, which moves along the plate using an electro-mechanical drive, controlled by a microcontroller, based This processes of pressure reduction in the hydraulic cylinder cavities are differently proportional and synchronized, the windows are located in one moving part, while the vertical planes of the joints made of the same type are provided for the parts of the highly atmospheric part, and the horizontal planes of the joints made of materials of different types are provided for the details of the low-atmospheric part.

The claimed composite design of a digital electronically controlled proportional hydraulic valve is a design of a prefabricated hydraulic valve, consisting of specially selected and manufactured elements and parts made both from metals / metal alloys and made from synthetic polymeric materials (plastics), suggesting a special architecture based on the physical separation of the high-atmospheric and low-atmospheric parts, a special method of connecting metal and non-metal structural elements and giving the function of plain bearings to channels in body parts made of polymers.

A digital electronically controlled proportional hydraulic valve (hereinafter referred to as CEPHR) is a control device as part of a hydraulic system, made on the basis of the fundamental solutions of the Digital Hydraulic Platform (hereinafter referred to as DHP) technology.

General arrangement and principle of operation of the Digital Electronically Controlled Proportional Hydrodistributor (CEPGR).

CEPGR consists of:

- housing (for each channel or common - monoblock), in which the low-atmospheric part is highlighted (Fig. 11):

- hydroflow digital control module (2);

- regulator digital control module (3);

- stepper electric motor with a pusher (for each channel);

- microprocessor that controls the electric motor (for each channel);

- digital feedback unit (for each channel);

- a control unit (1) of a hydraulic valve with "geometric programming" of flow characteristics - a prefabricated block-regulator with a hollow rectangular spool (high-atmospheric part) for each channel (Fig. 10).

Composition and principle of operation:

Regulator unit - The block regulator is part of a digital electronically controlled proportional hydraulic valve (CEPGR).

Figure 1 shows the connection diagram of the Regulator assembly (1) to the cavities of the executive hydraulic motor (for example, a hydraulic cylinder), where P - pressure lines (4), T - drain lines (5).

1 - Regulator node

4 - Pressure lines "P"

5 - Drain lines "T".

The nature of the operation of the executive hydraulic motor depends on the area and configuration of the throttling windows of the hydraulic regulator. The executive part of the hydraulic motor makes a movement when creating a pressure difference in the cavities. The outlet pressure difference is controlled by a regulator assembly.

The regulator assembly consists of two hermetically pressed plates with access windows:

- the distribution plate is fixed.

- the regulatory plate moves along the plate with the help of an electro-mechanical drive controlled by a microcontroller based on the data of the Digital Feedback Unit. The pressure reduction processes in the cavities of the hydraulic cylinder are inversely proportional and synchronous, since the regulator windows are located in one moving part.

On FIG. 2:

4 - Pressure lines "P"

5 - Drain lines "T"

6.7 - Regulatory windows

8 - Stationary plate

9 - Regulatory plate

Fixed distribution plate (8), in which "P" - windows of pressure lines (4), "T" - windows of drain lines (5) movable regulatory plate (9), in which there are regulatory windows (6,7).

On FIG. 3 - shading indicates the area of window overlap.

4 - Pressure lines "P"

5 - Drain lines "T"

6.7 - Regulatory windows

A feature of this regulator is the ability to geometrically lay down the law of development of the flow characteristics. The control window (6) of the movable plate can be rectangular in the case of a linear flow characteristic or have a profile that repeats the flow characteristic curve. The area of mutual overlap of windows, provided that the movable window is shifted along the X axis, with its geometric shape repeats the function of the regularity of development of the flow characteristic of the regulator.

On FIG. Figure 4 shows an example of overlapping flow windows, which creates a profile whose geometric shape corresponds to the graph of the flow characteristic function.

4 - Pressure line "P"

5 - Drain line "T"

6 - Regulatory window

Composition and principle of operation of the prefabricated Block-Regulator with a hollow rectangular spool.

There are no raw surfaces in the design of the prefabricated Block-Regulator with a hollow rectangular spool. In the manufacture of the case, casting is not used, there are no undercuts and internal hidden cavities.

The housing of the Block-Regulator is a prefabricated structure, so the accuracy of the cut-off edges of the hydraulic fluid passage windows is ensured within the range of up to 0.005 mm.

The edge is formed straight or corresponding to the regularity of the consumption characteristics. The accuracy of the cutting edges allows you to accurately determine the level of spool overlap (positive, zero or negative overlap).

On FIG. 5 shows a diagram of a prefabricated Block-Regulator with a hollow rectangular spool (10).

10 - Hollow rectangular spool

8 - Spreading plates

A feature of the Block-Regulator is the hollow design of the spool, which allows for complex four or more position switching. At the same time, the operation of the Regulator Block is controlled by an electronic-mechanical drive controlled by the processor based on sensor data.

On FIG. 6 shows the connection diagram of the control plates of the body of the prefabricated block-regulator with a rectangular spool and the multivariance of directions for the passage of hydraulic fluid.

The principle of operation of the prefabricated Block-Regulator with a hollow rectangular spool:

hydraulic fluid under pressure is supplied to the cavity of the receiving distribution plate. Further, the liquid flow is dosed by the cut-off edge of the inlet window of the hollow spool, passes through its internal volume and is dosed by the cut-off edges of the output windows of the hollow spool, being distributed into one or more receiving cavities of the tiles of the Block-Regulator.

In combination with the digital electronic control PAK "Digital Hydraulic Control Unit", which includes the Block-Regulator, a device for high-precision proportional dynamic control of the hydraulic motor operation is created.

The regulation of flows in the hydraulic system is carried out by TsEPGR, which is part of the hardware and software complex "Digital Hydraulic System Control Unit" (PAK TsBUG).

Fig. 7 shows schematic block diagrams of a traditional analog electrically controlled hydraulic valve and a Digital Hydraulic Platform (DHP) controlled hydraulic system.

1 - Regulator;

11 - Digital control;

12 - Digitization module;

13 - Hydraulic pump

14 - Electric analog control;

15 - Hydraulic motor;

16 - Hydraulic control;

17 - Hydrocompensation;

18 - Traditional analog electric control of the hydrodistributor;

19 - Digital Hydraulic Platform (DHP) technology;

Figure 7 shows the fundamental differences between hydraulic systems with a proportional valve of traditional architecture and architecture "Digital Hydraulic Platform" ("DHP").

On FIG. Figure 8 shows a block diagram of a hydraulic system controlled by the “Digital hydraulic system control unit” hardware and software complex and the functional compatibility of the PAK TsBUG with various hydraulic components, including those from different manufacturers.

22 - Unregulated pump;

23 - Adjustable pump with an inclined block;

24 - Adjustable swashplate pump;

25 - Non-reversible motors;

26 - Reversible motors;

27 - General industrial hydraulic cylinders;

28 - Hydraulic cylinders with the function of "following drive";

29 - Special dynamic reciprocating hydraulic drives;

30 - High-speed hydraulic dampers with software-variable characteristics;

31 - BCC (digital switching unit);

32 - External programmable control panel;

33 - TsBOS (digital feedback unit);

34 - PPB (software-processor unit);

35 - software (software);

36 - TsPEGR (digital proportional electronically controlled hydraulic valve);

37 - PAK TsBUG.

In CEPHR, the entire circuit of hydraulic logic and compensation is excluded due to the fact that its function is directly performed by the Programming and Processing Unit with special software, which, in addition, allows for continuous analysis and control of the operation of actuators without remote sensors and automatically adjusts the operation of the hydraulic system, taking into account changing operating conditions.

As a result, the use of fundamental solutions based on the "DHP" technology in the design of the CEPGR provides:

- exclusion of all elements and details of the analog hydraulic logic circuit (hydraulic control) from the design of the CEPHR;

- the possibility of physical geometric isolation of the high-atmospheric and low-atmospheric parts of the CEPGR;

- reduction in the number of small and high-precision structural elements and the total number of parts (by several times);

- rejection of complex / expensive materials and processing technologies in the production of elements and parts of the CEPGR.

On the basis of the above, it became possible to create a composite structure of the CEPHR.

The result of using the composite structure of the CEPHR are:

- creation of a prefabricated device in which a significant part of the volume of the structure is made of synthetic polymers;

- creation of a prefabricated device, in which the polymer housing of the low-atmospheric part of the proportional hydraulic unit itself performs the function of a plain bearing for steel moving parts;

- increasing the environmental friendliness of the product - CEPGR through the use in its design of materials that are the result / recyclable and non-polluting the environment;

- increasing the economic efficiency of CEPGR due to the use in the design of a material that has a significantly lower cost, less weight, increased resistance to aggressive environments than metal/metal alloys;

- the use of material with the possibility of its processing both by traditional methods (milling, drilling, boring, etc.), and by methods typical for the processing of polymers (injection molding, sintering, the use of additive technologies).

Thus, the technical problems solved in the proposed solution:

- separation of the hydraulic valve into high-atmospheric and low-atmospheric parts with the preservation of all operational properties, but with a decrease in the proportion of parts made of metal alloys to a value of not more than 35% of the total volume of the product material;

- complete exclusion from the design of the hydraulic distributor of channels and parts of the accompanying hydraulic control and hydraulic compensation, which prevent the physical isolation of the low-atmospheric part suitable for manufacturing from polymeric materials;

- replacement of a significant part of the body parts of the hydraulic distributor with parts made of synthetic polymers;

- creation of a method for reliable hermetic joining of parts made of metal alloys and synthetic polymers;

- the use of channels in the polymer housing of the low-atmospheric part as a plain bearing for moving steel parts.

The technical result of the claimed technical solution are:

- separation of the hydraulic valve into high-atmospheric and low-atmospheric parts with the preservation of all operational properties, but with a decrease in the proportion of metal parts by no more than 35% of the total volume of the product material;

- performance by channels in the low-atmospheric part of the body of the function of plain bearings for moving metal parts;

- use of cost-effective materials without loss of operational properties of the valve;

- use in the design of the valve of materials suitable for recycling and / or being a product of recycling;

Composite design of a digital electronically controlled proportional valve.

Composition and principle of operation.

If we consider the device of a traditional hydraulic valve, we can see that its body (cast iron, steel or aluminum) is pierced by hydraulic control channels, and also, the valve body is also a housing for a hydraulic compensator, hydraulic control flow reducing valves, “or” hydraulic control valves, etc. This is a single indivisible system, united by internal channels (Fig. 9), where the hydraulic control channels are marked in red.

The use of digital electronic control of the hydraulic valve allows you to completely exclude from its design the elements, parts and channels of the associated hydraulic control and hydraulic compensation, which are characteristic of the traditional design of the hydraulic valve. Thanks to this, it becomes possible to zone the valve body and divide it physically and geometrically into two parts:

- high-atmospheric, made of metal / metal alloy;

- low-atmospheric, made of materials with lower requirements for structural strength. For example, from polymeric materials.

The composite design of the hydraulic valve device allows you to create both a sectional - modular, and a monoblock layout of a multi-channel hydraulic valve.

For clarity, the composition and principle of operation of the claimed technical solution is illustrated by the example of the universal section of the sectional CEPGR (Fig. 10 and Fig. 11).

The removal of the digital control drive of the regulator to the low-atmospheric part allows reducing the proportion of metal parts to 35% of the total material volume of the device.

The main components occupying the structural volume are the low-pressure casing, the regulator digital control module and the digital flow control module. (Fig. 10).

On FIG. 10 are marked:

High-atmospheric part (highlighted in red) 1 - block - regulator;

Low-atmospheric part (highlighted in green) 2 - hydroflow digital control module;

3 - digital controller control module.

Cases of these modules are made using polymeric materials. Channels in the polymeric material of the housing act as a plain bearing for steel moving parts.

On FIG. 11 marked:

20 - Vertical planes of parts joining, one level of pressure;

21 - Horizontal planes of parts joining, different pressure levels.

In the well-known existing analogues, the channels in the body elements are also used as bearings, but the channels are made by casting special cast irons under pressure, followed by grinding.

In the case of the composite structure of the CEPGR, the channel in the plastic is made by a simple reamer without additional processing.

To exclude possible stresses caused by the difference in the coefficients of thermal expansion of materials, parts of different types (high-atmospheric and low-atmospheric) are joined in the same horizontal plane using a modular type of installation through O-rings. To pass hydroflows of the same pressure between themselves, parts of the same type in sections are joined through vertical side planes (Fig. 11).

A special design solution is the method of joining metal and polymer parts. There are essentially no threaded holes in polymer parts. Each polymer part is an insert between two metal parts tightened by threaded connections between themselves.

Applied materials.

The composite design of the CGGR allows the use of a wide range of materials:

- for the high-atmospheric part, aluminum alloys, cast irons, alloyed and stainless steels can be used.

- for the manufacture of the low-atmospheric part, it is possible to use polyoxymethylenes, polyamides and polyurethanes, suitable for processing both by traditional methods (milling, boring), and by methods characteristic of polymers (injection molding, sintering, manufacturing using additive technologies).

Thus, the claimed composite design of a digital electronically controlled proportional valve is a prefabricated valve device based on a combination in a single design of parts made from metals / metal alloys and parts obtained from synthetic polymeric materials, with a physical geometric division of the structure into high-atmospheric and low-atmospheric parts, with an original way of joining parts of the same type of material in the vertical plane, and parts of different types - in the horizontal, as well as giving the low-atmospheric polymer part of the housing a function plain bearing for moving steel parts.

PRACTICAL APPROBATION (implementation example).

By order of JSC "ToMeZ" (Joint-Stock Company "Tosnensky Mechanical Plant", Russian Federation, Leningrad Region) serially producing road-cleaning and municipal equipment, based on the Terms of Reference dated July 27, 2022. strength tests of the low-atmospheric part of the CPEGR made of polyoxymethylene and the functionality of the CPEGR assembly were carried out (test reports No. 1-8 dated October 12, 2022) on an experimental test bench.

The composition of the experimental test stand:

• hydroelectric power station consisting of an electric motor with a power of 20 kW and driven unregulated hydraulic pump HDS-64;

• hydrodistributor of manual inclusion Р-80 with the safety valve;

• CPEGR with a low-atmospheric part made of polymer;

• test closed safety box;

• channel monometer DM-93-063-1 (up to 250 MPa);

• high pressure connecting sleeves;

As a result of the tests, it was established:

• at a maximum operating pressure of 2.5 MPa in the low-atmospheric part of the CEPGR, its design withstood a fivefold excess of the operating pressure, after which it safely collapsed, allowing a leak along one of the edges;

• before the destruction of the low-atmospheric part of the CEPGR, it operated normally with a variable load and in different modes, maintaining the established parameters of the hydraulic system.

Claims (1)

A device for a digital electronically controlled proportional hydraulic valve (CEPHR), which includes a housing, characterized in that it contains an interconnected digital hydraulic flow control module, a digital regulator control module, a stepping motor with a pusher on each channel, a microprocessor that controls the electric motor on each channel, a digital feedback unit on each channel, while the high-atmospheric and low-atmospheric parts are allocated in the housing, while the high-atmospheric and low-atmospheric parts are joined in one horizontal plane using a modular type of installation through O-rings, and to pass hydraulic flows of the same pressure between themselves, parts of the same type in sections are joined through vertical side planes, the control unit of the hydraulic valve with “geometric programming” of flow characteristics, which is a prefabricated block-regulator with a hollow rectangular spool for each channel and forms a high-atmospheric part, while the regulatory unit consists of two hermetically pressed plates with throughput windows: distribution plates of a fixed and a control plate, which moves along the plate with the help of an electromechanical drive controlled by a microcontroller based on data from a digital feedback block, while the processes of pressure reduction in the cavities of the hydraulic cylinder are inversely proportional and synchronous, the windows of the regulators are located in one moving part, while for the parts of the high-atmospheric part, vertical planes of joining of parts made of materials of the same type are provided, and for parts of the low-atmospheric part, horizontal planes of joining of parts made of different types of materials.