a r t i c l e i n f o a b s t r a c t
Article history: The paper refers to four-port solenoid pilot operated valves, which are subplate mounted in a hydraulic
Received 11 December 2013 system in accordance with the ISO 4401 standard. Their widespread use in many machines and devices
Accepted 1 July 2014 causes a continuing interest in the development of their design by both the scientific centers and the
Available online 23 August 2014
industry. This paper presents an innovative directional control valve based on the use of logic valves
and a methodology followed for the design of it by using Solid Edge CAD and ANSYS/Fluent CFD software.
Keywords: The valve design methodology takes into account the need to seek solutions that minimize flow resis-
Hydraulic valve
tance through the valve. For this purpose, the flow paths are prepared by means of CAD software and
Directional control valve
Logic valve
pressure-flow curves are determined as a result of CFD analysis. The obtained curves are compared with
CFD analysis the curves available in the catalogs of spool type directional control valves.
The new solution allows to replace the whole family of spool type four-port directional control valves
by one valve built of logic valves. In addition, the innovative directional control valve provides leak-proof
shutting the flow paths off and also it can control flow rate and even pressure of working liquid. A
prototype of the valve designed by the presented method has been made and tested on the test bench.
The results quoted in the paper confirm that the developed logic type directional control valve is able
to meet all designed connection configurations, and the obtained pressure-flow curves show very good
conformity with the results of CFD analysis.
Ó 2014 Elsevier Ltd. All rights reserved.
1. Introduction and greater speed of control, and the ability to build special sys-
tems for large capacities of the volumetric flow rate, even several
Directional control valves are components of virtually any thousand liters per minute [11–14]. The logic valves are relatively
hydraulic system and hence they are subject to continuous devel- new solutions, which are being systematically introduced to
opment. A lot of scientific papers are dedicated to the issues of hydraulic controls and drives.
their performance characteristics improvement, such as papers of A single logic valve has a simple structure that allows control of
Amirante et al. [1–3], wherein CFD (Computational Fluid Dynam- the flow direction through one flow path, depending on the given
ics) methods are more and more often used to analyze the design pressure control signal. Due to the fact that the usual working ele-
of directional valves. The similar trends in the application of CFD ment has poppet type closing system, it is possible to obtain high
methods in the development of hydraulic system components internal tightness with almost no leakage. A single logic valve is
can be seen in the papers of, among others, Del Vescovo et al. [4] usually not able to fulfill the function of a directional control valve
Chattopadhyay et al. [5] and Pan et al. [6]. which controls the direction of movement of a hydraulic cylinder
In the recent years there has been a growing interest in the or motor. Using a sufficient number of logic valves, theoretically,
technique based on logic valves for slip-in mounting, especially we can build a directional control valve for these advanced control
the poppet type ones, which is reflected in the catalogs of manufac- functions [7,10,15]. Their assembly as a functional unit, such as
turers of hydraulic components, for example [7–10]. The develop- four-port hydraulic directional control valve, is a relatively com-
ment of those creates the possibility of higher internal tightness plex task [16]. Proposals of ready-made solutions are rare and, fur-
thermore, does not take into account the applicable standards [17].
Application of ISO 4401 standard [18] enables mounting and
⇑ Corresponding author.
connecting many different spool type directional control valves,
E-mail addresses: lisowski@mech.pk.edu.pl (E. Lisowski), czyzycki@mech.pk.
_
edu.pl (W. Czyzycki), janusz.rajda@ponar-wadowice.pl (J. Rajda).
as well as valves with different functions, to one type of subplate.
http://dx.doi.org/10.1016/j.enconman.2014.07.008
0196-8904/Ó 2014 Elsevier Ltd. All rights reserved.
906 E. Lisowski et al. / Energy Conversion and Management 87 (2014) 905–913
Nomenclature
Using ISO 4401 standard, the innovative solution allowing to (Fig. 2). Those are presented in Fig. 4. One valve can realize maxi-
replace of the whole family of spool type directional control valves mum 3 various combinations of connections. To have possibility of
by one unit is proposed. This is possible because, when using many more ones, there is necessity to use respectively more valve types.
logic valves to construct a directional control valve, one can control
each of them individually to create many configurations of flow
3. Leakproof logic valves
paths. In this paper a methodology for implementing such a solu-
tion will be presented for selected flow range up to 450 dm3/min
The current hydraulic market offers many technological solu-
and pressure of 35 MPa.
tions of logic valves [7–9] with different nominal sizes (Fig. 6),
for flow up to 20,000 dm3/min. For the sake of the study, a solution
capable of providing internal leak tightness between relevant ports
2. Spool valves according to ISO 4401 standard has been selected (Fig. 5). The tightness is achieved on the one side
in a conical seat 1 which mates with the edge of the conical end of
The valves designed for installation by this standard are offered the piston 2, on the other side by using a low friction seal 3
by a lot of companies, including such well-known ones as Bosch between the sleeve 1 and the cylindrical part of the piston 2. To
Rexroth [7], Eaton [8], and Kawasaki [9]. The ISO standard allows obtain complete internal leak tightness of valve, it still will be nec-
for interchangeable use of technological solutions from different essary to seal the pilot control line connected to the port X. It can
companies and without having to disassemble or change the pip- be accomplished by using a poppet valve as a pilot (Fig. 7).
ing of the system. This standard provides also the possibility of
building a layer of additional valves (pilot operated check valves,
throttle/check valves, pressure control valves, etc.). 4. Combinations of logic valve connections
The design of spool type pilot operated directional control
valves is relatively simple. The typical hydraulic directional control Using several logic valves, we can obtain a large number of flow
valve (Figs. 1 and 2) consists of a main stage 1 with body, wherein path combinations. In order to replace all the functions performed
the control spool is placed, and a built-on pilot valve 2. These by directional control valves from WEH22 family, it will be neces-
valves can be made with different spools having different connec- sary to use six logic valves. For the valve constructed with the logic
tion configurations of the ports. Fig. 3 shows a set of frequently units the code is L6-WEH22, where L6 stands for the number of
used types of 2- and 3-position valves offered by various compa- logic valves used, while WEH22 means compatibility with the
nies. Analyzing the flow paths, it can be determined that they meet standard hydraulic spool valve.
13 combinations of connections between four ports P, A, B, T Schematic diagram of the designed directional control valve L6-
WEH22 can be found in Fig. 8. The possibility of connections using
the logic valves are shown in the graph in Fig. 9. Considering all
combinations of solenoid switches, the number of possible
connection variants equals 64. Some of these connections may
Fig. 3. Frequently used hydraulic schemes for 2- and 3-position spool type To check the ability to implement the solution, the models of
directional control valves and their symbols used in catalogs [10,19]. components such as logic valves, solenoid pilot valves, and shuttle
valves, were made in SolidEdge software. Then they were placed in
a space basically defined by the connection pattern, according to
ISO standard in such a way that it was possible to design the body
with internal channels (Fig. 10).
The project is inspired by the solution of four-port directional
control valve built of logic valves presented in the paper [16]. Four
logic valves L1, L2, L3, L4 (Fig. 10) placed parallel to each other, per-
pendicular to the subplate surface, in a row are used to build the
valve. Putting more of the valves in a row is limited by the overall
Fig. 4. Configurations of connections between the four ports for schemes of the
dimensions. In the cover above the logic valves there are four pilot
spool type valves from Fig. 3.
valves E1, E2, E3, E4. To obtain more functions, two additional logic
valves: L5 and L6, are used. Those are placed parallel to the sub-
plate surface, opposite each other in a separate plate 2 (Fig. 11)
prove useless in practice. Taking into account the most useful com- under the main valve block 1. Pilots to the logic valves L5 and L6
binations (Table 1), the selected connections are shown corre- are mounted to the plate 2 by means of blocks 3 and 4 (Fig. 11).
spondingly to the technological solutions used in the spool type The valve built-in this way, has mounting pattern in accordance
valves. As presented in the Table 1, it enables the realization of with ISO (Fig. 12). Free space in the body 1 is left to build in two
all connection variants for the spool type valves shown in Fig. 4 shuttle valves S1 and S2 to select a pressure supplied to the control
and also makes connections between paths AB and AB + PT which system. Additionally, logic valves can be used as pressure control
usually are not performed by the normal spool valves. The realiza- valves. For example, for the logic valves L5 and L6 in the body 3
tion of the different connection configurations of four ports (A, B, P, and 4 (Fig. 11) the pilots of pressure relief valves Z1 and Z2
T) by using the logic valves L1–L6 is obtained by energizing the (Fig. 10) are built-in, functioning as pressure relief on PT and AB
appropriate solenoids E1–E6. paths.
6. CFD analysis
Fig. 7. Leak proof logic valve assembly with internal pilot supply: 1 – logic valve, 2
– poppet valve, and 3 – shuttle valve. the nodes. What follows is that the initial heights for an uniform
mesh will be approximately the same, whereas the initial heights
for a varying mesh will vary [16,22]. The Curvature Size function
is used to generate mesh for flow paths. This function analyses cur-
vature on edges and faces and calculates element sizes on those, so
that the size will not exceed the maximum size or the normal cur-
vature angle, which can be defined by the user or computed auto-
matically by the Mesher.
Table 1
Configuration of solenoid switches for the implementation of appropriate flow paths: 1 – on and 0 – off.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Symbol
E1 0 1 0 0 0 1 0 1 0 1 0 1 0 0 0
E2 0 0 0 1 0 0 1 0 1 1 0 1 0 0 0
E3 0 0 1 0 0 0 1 1 0 0 1 1 0 0 0
E4 0 0 0 0 1 1 0 0 1 0 1 1 0 0 0
E5 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1
E6 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1
Fig. 11. Design of directional control valve L6-WEH22: 1 – logic valve block L1–L4,
2 – logic valve block L5 and L6, 3 and 4 – block with stroke limiter and pressure
pilots for logic valves L5 and L6, and 5 – pilot valve block for L1–L4.
Fig. 13. Finite element mesh for the flow path PA: Nodes 236 725 and elements 755
described in modelling turbulent production in the k—e models. Gb 535.
is the generation of turbulence kinetic energy due to buoyancy, cal-
culated as described in effects of buoyancy on turbulence in the k—e
models. Y M represents the contribution of the fluctuating dilatation 6.3. Boundary conditions
in compressible turbulence to the overall dissipation rate, calcu-
lated as described in effects of compressibility on turbulence in The calculation has been conducted for four values of inlet
the k—e models. C 1e ; C 2e and C 3e are constants. Sk and Se are the velocity of hydraulic liquid: 4, 8, 12 and 16 m/s (Velocity Inlet).
turbulent Prandtl numbers for k and e, respectively. Sk and Se are For outlet boundary condition type Pressure Outlet has been
user-defined source terms. The turbulent (or eddy) viscosity, lt , is assumed – constant pressure on outlet p ¼ 0:1 MPa. Intensity of
computed by combining k and e as follows: turbulence has been assumed for calculation basing on the value
2 of 2% for the scale length of 2 mm. Remaining assumptions:
k
lt ¼ q C l ; ð3Þ
e no slip on walls,
where C l is a constant. the liquid is incompressible (hydraulic oil),
ANSYS/Fluent standard model of turbulence k—e has been cho- the liquid properties are constant,
sen. The model constants have the following default values the model is in condition of thermal equilibrium,
[16,26]: C 1e ¼ 1:44; C 2e ¼ 1:92; C 3e ¼ 1; C l ¼ 0:09; Sk ¼ 1:0; Se ¼ 1:3. viscosity of hydraulic liquid is 41 mm2/s.
910 E. Lisowski et al. / Energy Conversion and Management 87 (2014) 905–913
Fig. 14. Finite element mesh for the flow path BT: Nodes 226 514 and elements 710
710.
Fig. 16. Velocity distribution along the stream line for the flow path PA.
Fig. 15. Pressure distribution on the walls of the flow path PA. Fig. 17. Pressure distribution on the walls of the flow path BT.
for path PA is shown in Fig. 16. The analysis of stream lines pre-
sented in the figure suggests that in the initial phase of the flow
velocity rose locally to above 30 m/s in the narrowings of the logic
from P port, the stream lines are arranged in parallel. After entering
valve as well as in the places of sudden changes in flow direction.
the logic valve of complex shape, its split follows.
A similar phenomenon occurs for the flow path BT (Fig. 18). At
flow line BT eddy of the flow stream is maintained along a whole 6.5. The characteristic curves of pressure losses
length of the passage from outlet of the valve up to T ports of the
directional control valve. The highest value of the fluid velocity Using the results of calculations performed in ANSYS/Fluent,
can be seen in the holes of the valve sleeve, both at the inlet and flow resistance curve is made. Fig. 19 shows the curves obtained
outlet. In the case of path BT (Fig. 18) a higher value of fluid veloc- from five points (point 0 and four points calculated) using the
ity can be observed in the rectilinear section of the path leading to approximation by polynomial equation of the least squares
the port T. This is the effect of narrowing the stream, which after method. The lowest pressure losses occur in the paths AB and PT,
passing through the windows of the logic valve body encounters while slightly higher pressure losses occur for the paths PA, AT
three consecutive path direction changes of angle of 90°. The aver- and PB and the largest for BT. Increased pressure losses in the path
age value of flow velocity at the valve inlet was 16 m/s while the BT result from larger number of the fluid flow direction bends at an
E. Lisowski et al. / Energy Conversion and Management 87 (2014) 905–913 911
8. Experimental tests
Fig. 20. Real directional control valves: left – valve L6-WEH22 and right – WEH22 with pilot operated check valve and double throttle check valve [7].
912 E. Lisowski et al. / Energy Conversion and Management 87 (2014) 905–913
Fig. 24. Comparison of pressure loss curves for the path PT, the results obtained: 1 –
from the experiment and 2 – from the CFD analysis.
Fig. 25. Pressure losses for spool type directional control valves WEH22E, WEH22G
Fig. 22. Comparison of pressure loss curves for the path BT, the results obtained: 1 –
and WEH22R [20].
from the experiment and 2 – from the CFD analysis.
Fig. 23. Comparison of pressure loss curves for the path PA, the results obtained: 1
– from the experiment and 2 – from the CFD analysis.
3
For comparison of pressure losses, common point is selected. It Fig. 26. Comparison of pressure losses at Q ¼ 300 dm = min for L6-WEH22 to
3 WEH22E, WEH22R and WEH22G.
is the volumetric flow rate of the value of Q ¼ 300 dm = min,
because the flow of this value is realized for the available catalog
3
data. Pressure loss for Q ¼ 300 dm = min for the valves WEH22E,
WEH22G, WEH22R range from 0:35 to 1:1 MPa, while for the valve 10. Summary
L6-WEH22 they range from 0:35 to 0:75 MPa (Fig. 26) and thus
vary quite considerably. Pressure losses for the paths AB and PT This paper presents a proposal of replacing the family of four-
for the logic type valve are much lower (more than 60%), for the port pilot operated spool type directional control valves by only
path AT similar value is obtained, while for the other paths are one directional control valve built of logic valves. In the design of
slightly higher than in the spool type valve. Therefore, it can be a new valve, which is coded as L6-WEH22, six logic valves con-
concluded that, for the paths AB and PT the logic type valve allows trolled by six 3/2 directional control valves poppet type as a pilot
for far more favorable performance characteristics, while others are applied. As a foundation for the design, it was assumed that
are comparable. the valve must be mounted on a standard ISO subplate [18], be
E. Lisowski et al. / Energy Conversion and Management 87 (2014) 905–913 913
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