Coupling behavior between adhesive and abrasive wear mechanism of aero-hydraulic spool valves

Leakage due to wear is one of the main failure modes of aero-hydraulic spool valves. This paper established a practical coupling wear model for aero-hydraulic spool valves based on dynamic system modelling theory. Firstly, the experiment for wear mechanism verification proved that adhesive wear and abrasive wear did coexist during the working process of spool valves. Secondly coupling behavior of each wear mechanism was characterized by analyzing actual time-variation of model parameters during wear evolution process. Meanwhile, Archard model and three-body abrasive wear model were utilized for adhesive wear and abrasive wear, respectively. Furthermore, their coupling wear model was established by calculating the actual wear volume. Finally, from the result of formal test, all the required parameters for our model were obtained. The relative error between model prediction and data of pre-test was also presented to verify the accuracy of model, which demonstrated that our model was useful for providing accurate prediction of spool valve's wear life. (C) 2016 The Authors. Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.

Finite Element Numerical Simulation and PIV Measurement of Flow Field inside Metering-in Spool Valve

The finite element method （FEM） and particle image velocimetry （PIV） technique are utilized to get the flow field along the inlet passage, the chamber, the metering port and the outlet passage of spool valve at three different valve openings. For FEM numerical simulation, the stream function ψ-vorticity ω forms of continuity and Navier-Stokes equations are employed and FEM is applied to discrete the equations. Homemade simulation codes are executed to compute the values of stream function and vorticity at each node in the flow domain, then according to the correlation between stream function and velocity components, the velocity vectors of the whole field are calculated. For PIV experiment, pulse Nd： YAG laser is exploited to generate laser beam, cylindrical and spherical lenses are combined each other to produce 1.0 mm thickness laser sheet to illuminate the object plane, Polystyrene spherical particle with diameter of 30-50 μm is seeded in the fluid as a tracing particles, Kodak ES 1.0 CCD camera is employed to capture the images of interested, the images are processed with fast Fourier transform （FFT） cross-correlation algorithm and the processing results is displayed. Both results of numerical simulation and PIV experimental show that there are three main areas in the spool valve where vortex is formed. Numerical results also indicate that the valve opening have some effects on the flow structure of the valve. The investigation is helpful for qualitatively analyzing the energy loss, noise generating, steady state flow forces and even designing the geometry structure and flow passage.

Thermal-hydraulic modeling and analysis of spool valve with sloping U-shape notch by bond graph

To increase the efficiency and reliability of the thermodynamics analysis of the spool valve, the precise function expression of the flow area for the sloping U-shape notch orifice versus the spool stroke and thermal-hydraulic bond graph based on the conservation of mass and energy were introduced. Subsequently, the connection rule for the bond graph elements and the method to construct the complete thermal-hydraulic system model were proposed. On the basis of heat transfer analysis of a typical hydraulic circuit containing the spool valve, the lumped parameter for mathematical model of the system was given. At last, the reliability of the mathematical model of the flow area and the thermal-hydraulic system for the sloping U-shape notch orifice on the spool were demonstrated by the test. The good agreement between the simulation results and experimental data demonstrates the validity of the modeling method.

Investigation into the Independent Metering Control Performance of a Twin Spools Valve with Switching Technology-controlled Pilot Stage

In hydraulic area,independent metering control(IMC)technology is an effective approach to improve system efficiency and control flexibility.In addition,digital hydraulic technology(DHT)has been verified as a reasonable method to optimize system dynamic performance.Integrating these two technologies into one component can combine their advantages together.However,few works focused on it.In this paper,a twin spools valve with switching technologycontrolled pilot stage(TSVSP)is presented,which applied DHT into its pilot stage while appending IMC into its main stage.Based on this prototype valve,a series of numerical and experiment analysis of its IMC performance with both simulated load and excavator boom cylinder are carried out.Results showed fast and robust performance of pressure and flow compound control with acceptable fluctuation phenomenon caused by switching technology.Rising time of flow response in excavator cylinder can be controlled within 200 ms,meanwhile,the recovery time of rod chamber pressure under suddenly changed condition is optimized within 250 ms.IMC system based on TSVSP can improve both dynamic performance and robust characteristics of the target actuator so it is practical in valve-cylinder system and can be applied in mobile machineries.

Flow field simulation and establishment for mathematical models of flow area of spool valve with sloping U-shape notch machined by different methods

Precise function expression of the flow area for the sloping U-shape notch orifice versus the spool stroke was derived.The computational fluid dynamics was used to analyze the flow features of the sloping U-shape notch on the spool,such as mass flow rates,flow coefficients,efflux angles and steady state flow forces under different operating conditions.At last,the reliability of the mathematical model of the flow area for the sloping U-shape notch orifice on the spool was demonstrated by the comparison between the orifice area curve derived and the corresponding experimental data provided by the test.It is presented that the bottom arc of sloping U-shape notch(ABU) should not be omitted when it is required to accurately calculate the orifice area of ABU.Although the theoretical flow area of plain bottom sloping U-shape notch(PBU) is larger than that of ABU at the same opening,the simulated mass flow and experimental flow area of ABU are both larger than these of PBU at the same opening,while the simulated flow force of PBU is larger than that of ABU at the same opening.Therefore,it should be prior to adapt the ABU when designing the spool with proportional character.

Development of a Novel Parallel-spool Pilot Operated High-pressure Solenoid Valve with High Flow Rate and High Speed

High-pressure solenoid valve with high flow rate and high speed is a key component in an underwater driving system.However,traditional single spool pilot operated valve cannot meet the demands of both high flow rate and high speed simultaneously.A new structure for a high pressure solenoid valve is needed to meet the demand of the underwater driving system.A novel parallel-spool pilot operated high-pressure solenoid valve is proposed to overcome the drawback of the current single spool design.Mathematical models of the opening process and flow rate of the valve are established.Opening response time of the valve is subdivided into 4 parts to analyze the properties of the opening response.Corresponding formulas to solve 4 parts of the response time are derived.Key factors that influence the opening response time are analyzed.According to the mathematical model of the valve,a simulation of the opening process is carried out by MATLAB.Parameters are chosen based on theoretical analysis to design the test prototype of the new type of valve.Opening response time of the designed valve is tested by verifying response of the current in the coil and displacement of the main valve spool.The experimental results are in agreement with the simulated results,therefore the validity of the theoretical analysis is verified.Experimental opening response time of the valve is 48.3 ms at working pressure of 10 MPa.The flow capacity test shows that the largest effective area is 126 mm2 and the largest air flow rate is 2320 L/s.According to the result of the load driving test,the valve can meet the demands of the driving system.The proposed valve with parallel spools provides a new method for the design of a high-pressure valve with fast response and large flow rate.

An Analysis of the Static and Dynamic Behavior of the Hydraulic Compensation System of a Multichannel Valve

Electro-hydraulic proportional valve is the core control valve in many hydraulic systems used in agricultural and engineering machinery.To address the problem related to the large throttling losses and poor stability typically associated with these valves,here,the beneficial effects of a triangular groove structure on the related hydraulic response are studied.A mathematical model of the pressure compensation system based on the power-bond graph method is introduced,and the AMESim software is used to simulate its response.The results show that the triangular groove structure increases the jet angle and effectively compensates for the hydrodynamic force.The steady-state differential pressure at the valve port of the new pressure compensation structure was 0.65 MPa.Furthermore,experimental results show that the pressure difference at the main valve port is 0.73 MPa,and that the response time is less than 0.2 s.It is concluded that the new compensation structure has good pressure compensation response characteristics.

考虑阀芯阀套径向间隙的对称均等负开口液压滑阀压力特性分析

考虑阀芯与阀套之间的径向间隙,建立具有对称均等负开口量的液压滑阀压力特性数学模型,得到了负开口滑阀的压力特性曲线族及其基本特征,分析了径向间隙和负开口量对滑阀压力特性的影响。结果表明:具有负开口量的液压滑阀的压力特性曲线在阀芯位移等于负开口量处存在拐点,在拐点前假设为层流流动,因此负载压力随阀位移变化曲线是线性的,在拐点后为紊流流动,因此负载压力与阀位移成非线性关系;负开口滑阀可弥补阀芯阀套径向间隙的泄漏量,其压力增益随着负开口量的增加而降低;所建立的数学模型,可为电液伺服阀、高端比例阀以及多路滑阀的研制和分析提供技术支撑。

高压阀口液动力补偿控制策略仿真分析

直动式比例伺服阀是一种新型的单级伺服阀,采用比例电磁铁或线性力马达直接驱动滑阀运动,具有成本低、频响高、抗污染能力强等优点,广泛应用于注塑机进给控制、轧机板厚控制系统等高速高精度液压控制系统中。传统的直动式比例伺服阀采用PID控制策略实现阀芯的精确位置控制,在高压大流量工况下(供油压力达到20 MPa、流量大于100 L/min),阀芯受到液动力扰动变得更加剧烈,易出现响应速度慢、阀芯抖动的现象,影响了比例伺服阀的控制精度。为了解决大液动力扰动的问题,提出了一种基于指数收敛干扰观测器的滑模控制器。通过建立阀芯动力学模型来设计滑模控制器,保证阀芯位置的高动态跟踪性能;使用基于指数收敛的干扰观测器,估计阀芯动力学模型中液动力的不确定性扰动,解决高压大流量工况下的阀芯液动力扰动补偿问题。搭建了比例伺服阀系统的联合仿真模型进行仿真验证,结果表明,提出的控制器可以解决高压大流量工况下阀芯液动力扰动对阀芯位置控制的干扰问题。

节流槽形状对液压滑阀卡滞力的影响

液压滑阀是液压系统中的关键控制部件之一,其结构简单可靠,易于实现流量、压力控制。但是运行过程中由于热负荷产生的微小变形会导致阀芯卡滞现象的出现。当阀芯发生卡滞现象时,可能会严重降低液压阀的精度和灵敏度。基于热-流-固耦合模型,分析了节流槽形状对液压滑阀卡滞力的影响。首先建立了阀内固定开度流道模型,计算获得了不同节流槽形状下阀内流动特性;其次,将流体分析得到的温度场信息作为边界条件加载到热分析中,得到阀芯上的温度分布特性;最后研究了不同节流槽形状下阀芯间隙的变形量,分析阀芯卡滞的变化,为减小阀芯卡滞措施的研究提供参考。

液压圆柱滑阀K-K型节流槽流量面积参数模型

针对K-K型节流槽流量系数复杂时变及结构参数强耦合的特征,采用流量面积参数模型(FAPM),开展了液压圆柱滑阀K-K型节流槽阀口流量压降特性研究。首先,推导出K-K型节流槽阀口面积的数学模型,并将其等效为3个单阶K型节流槽阀口面积的组合形式;其次,基于计算流体动力学(CFD)和响应面模型(RSM),建立了极限饱和流量下K-K型节流槽的FAPM模型;最后,通过对FAPM模型的分析,得到组合型节流槽阀芯结构与流量压降的映射关系。研究结果表明:当入口体积流量大于7.31 L/min时,满足极限流量饱和条件,此时流量系数与入口体积流量无关;当入口体积流量分别为20、30、50 L/min时,FAPM模型预测的K-K型节流槽阀口压降与CFD仿真值的平均误差均控制在7%以内。该模型完成了对K-K型节流槽阀芯结构的近似表达,并可应用于其他类型的组合型节流槽。

改进矩形节流槽滑阀阀口的流量特性仿真分析

针对滑阀的静态特性能够影响液压伺服系统性能的问题,主要采用软件模拟仿真的方法分析了在滑阀阀芯台肩处设置改进矩形预开口的情况下,获得随着阀芯位移的变化阀芯内部流场的压力、流速以及流量的分布规律,从而得到阀芯的应变情况,得出不同过流面的压力及流速变化规律,并仿真分析了在无预开口情况下对应的压力,流速,流量等参数的分布情况,分析了在开设圆形预开口与无预开口情况下对液压阀流量增益的影响。仿真结果表明滑阀采用改进矩形槽结构之后,能明显改善其内部的流场分布、有效减小了阀芯变形,从而提高换向阀的动静态性能。

基于ADRC和模型预测控制的直驱伺服阀振荡抑制研究

直驱伺服阀因构造简单、抗污染能力强、输出功率大等突出优势,逐渐扩展其应用场景。作为飞控系统的关键部件之一,电液伺服阀的特性与可靠性直接关乎飞行性能与安全。本文针对某型航空用双系统直驱伺服阀存在的阀芯振荡问题,探究基于方法的伺服阀振荡抑制策略。建立了该直驱伺服阀系统的部件级数学模型,并与突变液流力模型联合运算;设计了自抗扰控制器(ADRC)和模型预测的复合控制方法,并与传统比例积分微分(PID)控制方法进行仿真对比。结果表明,ADRC和模型预测的复合控制方法对直线电机电流的高频小范围调节可有效抵消突变液流力对阀芯运动的影响,从而为直驱伺服阀在复杂受力环境下的控制器设计提供理论参考。

双阀芯先导笼式调节阀的设计仿真与试验

为解决高温高压工况下调节阀的不平衡力及密封力难以达到所需泄漏等级的问题,设计了一种大阀芯和小阀芯分段配合工作、充分利用阀前介质压力增加阀座密封力的双阀芯先导笼式调节阀。文中给出了调节阀的不平衡力计算公式、流量方程,分析了其流量特性,并对阀内流体的流动进行了仿真,分析了流体流过调节阀后的压力损失;对大阀芯内腔进行了流体流动仿真,分析了阀前压力、内腔温度以及密封力的变化;对大、小阀芯进行了运动仿真,分析了执行器驱动力、阀芯轴向合力和大阀芯速度的变化。常温介质阀体耐压试验和阀座泄漏量试验结果表明,阀体均无可见泄漏和变形,泄漏量设定为10滴/min时,3次实测泄漏量分别为1、1和2滴/min。高温介质阀座泄漏量试验结果表明,泄漏量设定为1.275 mL/min时,250℃高温水蒸气的3次实测泄漏量分别为0.11、0.11和0.13 mL/min,300℃高温水蒸气的3次实测泄漏量分别为0.19、0.19和0.22 mL/min,实测泄漏量均小于设定值。文中提出的双阀芯先导笼式结构增强了调节阀的密封力,阀体耐压强度和阀座密封性能均满足使用要求。

滑阀式卷扬平衡阀的设计及其在旋挖钻机上的试验研究

针对旋挖钻机主卷扬系统,设计了一种滑阀式卷扬平衡阀。在台架上进行了一般性试验和可靠性试验之后,将样件装在某旋挖钻机上进行带载试验。试验过程中出现了主卷扬启动憋压、下放抖动、失速溜杆现象,分析了引起这些现象的原因,并针对性地制定了解决方案,经过优化的平衡阀达到了优越的使用效果。

不同气隙下的高压电磁阀动作时间响应特性研究

为探究不同气隙下对电磁阀的动作时间响应的问题,针对高压气动电磁阀的阀杆进行受力分析。基于不同气隙的电磁铁吸力的测试结果,对阀门中的阀杆进行了ANSYS仿真,对不同气隙下的阀杆应力和变形量进行了分析。进行了电磁阀的动作时间测试,对不同气隙的电磁阀启闭时间进行了测试,分析了高低压2种工况下的启闭情况。通过试验发现,工作气隙在0.3~0.4 mm下较为适宜,为后续高压电磁阀的装配和使用提供了理论指导。

纯电动商用车电磁阀阀芯失效故障分析

文章针对纯电动商用车变速器电磁阀阀芯故障失效案例,通过走访调查、故障件复现、试验分析、对比试验,依靠部件工作原理,分析产品的失效原因,指出最终影响因素,最后提出此类问题的解决方案。

2D DIGITAL SIMPLIFIED FLOW VALVE

The 2D digital simplified flow valve is composed of a pilot-operated valvedesigned with both rotary and linear motions of a single spool, and a stepper motor under continualcontrol. How the structural parameters affect the static and dynamic characteristics of the valve isfirst clarified and a criterion for stability is presented. Experiments are designed to test theperformance of the valve. It is necessary to establish a balance between the static and dynamiccharacteristics in deciding the structural parameters. Nevertheless, it is possible to maintain thedynamic response at a fairly high level, while keeping the leakage of the pilot stage at anacceptable level. One of the features of the digital valve is stage control. In stage control thenonlinearities, such as electromagnetic saturation and hysteresis, are greatly reduced. To a largeextent the dynamic response of the valve is decided by the executing cycle of the control algorithm.

Study on a Novel Digital Electro－Hydraulic Pressure Valve with a Capillary Damping Tube Regulating Pressure

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滑阀阀芯凹角结构CFD仿真分析与优化设计

液压滑阀作为基础的液压放大元件之一,广泛应用于液压伺服系统。液压滑阀通过节流原理实现对流量或压力的控制,同时阀口节流作用会导致能量损失和剧烈漩涡,影响液压系统的工作性能。以液压滑阀阀芯为研究对象,采用有限元分析软件Fluent研究阀芯凹角结构对滑阀内部流场流动特性和能量损失特性的影响,其次基于粒子群算法对阀芯凹角结构参数进行智能寻优。研究结果表明:“斜边+弧边”形结构阀芯可以有效平缓流场,抑制阀口处漩涡的发生,当阀芯凹角斜线角度为57.4°,圆弧半径为1.14 mm,阀口处最大湍流动能较常规滑阀降低25%。研究成果将为液压阀阀芯结构的设计和优化提供思路。