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Research Papers

Design of a Crank-Slider Spool Valve for Switch-Mode Circuits With Experimental Validation

[+] Author and Article Information
Shaun E. Koktavy

Department of Mechanical Engineering,
University of Minnesota,
Minneapolis, MN 55455
e-mail: Kokta002@umn.edu

Alexander C. Yudell

Department of Mechanical Engineering,
University of Minnesota,
Minneapolis, MN 55455
e-mail: Yudel004@umn.edu

James D. Van de Ven

Department of Mechanical Engineering,
University of Minnesota,
Minneapolis, MN 55455
e-mail: vandeven@umn.edu

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT, AND CONTROL. Manuscript received January 3, 2017; final manuscript received November 2, 2017; published online December 22, 2017. Assoc. Editor: Heikki Handroos.

J. Dyn. Sys., Meas., Control 140(6), 061008 (Dec 22, 2017) (9 pages) Paper No: DS-17-1005; doi: 10.1115/1.4038537 History: Received January 03, 2017; Revised November 02, 2017

A challenge in realizing switch-mode hydraulic circuits is the need for a high-speed valve with fast transition time and high switching frequency. The work presented includes the design and modeling of a suitable valve and experimental demonstration of the prototype in a hydraulic boost converter. The design consists of two spools driven by crank-sliders, designed for 120 Hz maximum switching frequency at a flow rate of 22.7 lpm. The fully open throttling loss is designed for <2% of the rated pressure of 34.5 MPa. The transition time is less than 5% (0.42 ms at 120 Hz) of the total cycle and the duty cycle is adjustable from 0 to 1. Leakage and viscous friction losses in the design are less than 2% of the rated hydraulic energy per cycle. The experimental results agreed well with the model resulting in a 3% variation in transition time. The use of the high-speed valve in a pressure boosts converter demonstrated boost ratio capabilities of 1.08–2.06.

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Figures

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Fig. 1

Simplified hydraulic pressure boost converter

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Fig. 2

Crank-slider valve base architecture

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Fig. 3

Relationship between number of ports in a row and the diameter of the ports in a row and diameter of the ports versus the required crank length to achieve a 5% transition ratio

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Fig. 4

The effect of crank length and radial clearance, on energy losses over a cycle

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Fig. 5

Energy loss over a cycle versus crank radius, with prescribed land lengths of two times the crank radius and a radial clearance of 10 μm

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Fig. 6

Secondary throttling loss components of a single flow path

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Fig. 7

Model predicted power losses as a fraction of flow power at rated pressure and volumetric flow rate

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Fig. 8

Valve validation hydraulic experimental setup

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Fig. 9

Valve validation experimental setup

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Fig. 10

Leakage hydraulic experimental setup

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Fig. 11

Experimental boost circuit hydraulic schematic

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Fig. 12

Run nine quasi-static CdA profile

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Fig. 13

Analytical and experimental quasi-static transition time comparison

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Fig. 14

Valve analytical and experimental quasi-static overlap comparison between flow paths A2 and B3

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Fig. 15

Comparison of analytical and experimental CdA at various flow rates

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Fig. 16

Experimental and analytical quasi-static leakage

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Fig. 17

System experimental pressures, D = 0.5, 83 Hz

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