Electrohydraulic Counterbalance and Pressure Relief Valve

BACKGROUND

Counterbalance valves are hydraulic valves configured to hold and control negative or gravitational loads. They may be configured to operate, for example, in applications that involve the control of suspended loads, such as mechanical joints, lifting applications, extensible movable bridge, winches, etc.

In some applications, the counterbalance valve, which may also be referred to as an overcenter valve, could be used as a safety device that prevents an actuator from moving if a failure occurs (e.g., a hose burst) or could be used as a load holding valve (e.g., on a boom cylinder of a mobile machinery). The counterbalance valve allows cavitation-free load lowering, preventing the actuator from overrunning when pulled by the load (gravitational load).

As an example, a pilot-operated counterbalance valve could be used on the return side of a hydraulic actuator for lowering a large negative load in a controlled manner. The counterbalance valve generates a preload or back-pressure in the return line that acts against the main drive pressure so as to maintain a positive load, which therefore remains controllable. Particularly, if a speed of a piston of the cylinder increases, pressure on one side of the cylinder (e.g., rod side) may drop and the counterbalance valve may then act to restrict the flow to controllably lower the load.

When a directional control valve is operating in a load-lowering mode, the pilot-operated counterbalance valve is opened by a pressurized pilot line. To protect both directions of motion of a fluid receiving device against a negative load, a counterbalance valve may be assigned to each of the ports of the fluid receiving device. Each counterbalance valve assigned to a particular port may then be controlled open via cross-over by the pressure present at the other port. In other words, a respective pressurized pilot line that, when pressurized, opens a counterbalance valve is connected to a supply line connected to the other port.

SUMMARY

The present disclosure describes implementations that relate to an electrohydraulic counterbalance and pressure relief valve. In a first example implementation, the present disclosure describes a valve. The valve includes: (i) a housing having a pilot port on an exterior peripheral surface of the housing; (ii) a sleeve disposed in the housing, where the sleeve defines a first port and a second port, where the first port includes a set of cross holes disposed in a radial array about an exterior peripheral surface of the sleeve, and where the second port is defined at a nose of the sleeve; (iii) a piston axially movable within the sleeve, where the piston defines a cavity therein, and where the sleeve defines a piston seat at which the piston is seated when the valve is in a closed state; (iv) a pilot pin received at, and axially movable in, the cavity of the piston, where the piston forms a pilot seat at which the pilot pin is seated when the valve is in the closed state; and (v) a solenoid actuator comprising a solenoid coil, an armature, and a solenoid spring, where the solenoid spring applies a biasing force on the pilot pin in a distal direction to seat the pilot pin at the pilot seat. When pressurized fluid is received at the first port, the pressurized fluid applies a first force on the pilot pin in a proximal direction opposite the distal direction, and when a pilot pressure fluid signal is received through the pilot port of the housing, the pilot pressure fluid signal applies a second force on the pilot pin in the proximal direction, such that when the first force and the second force overcome the biasing force of the solenoid spring, the pilot pin moves axially in the proximal direction off the pilot seat, thereby causing the piston to move off the piston seat and follow the pilot pin in the proximal direction, allowing flow from the first port to the second port. When an electric signal is provided to the solenoid coil, the armature applies a third force on the solenoid spring in the proximal direction, thereby reducing the biasing force that the solenoid spring applies on the pilot pin.

In a second example implementation, the present disclosure describes a valve. The valve includes: (i) a housing having a pilot port on an exterior peripheral surface of the housing; (ii) a main stage comprising: (a) a main sleeve disposed in the housing and defining a first port and a second port, where the first port includes at least one cross hole disposed on an exterior peripheral surface of the main sleeve, and where the second port is defined at a nose of the main sleeve, and (b) a piston axially movable within the main sleeve, where the piston defines a cavity therein, and where the main sleeve defines a piston seat at which the piston is seated when the valve is in a closed state; (iii) a pilot stage comprising a pilot pin received at, and axially movable in, the cavity of the piston, where the piston forms a pilot seat at which the pilot pin is seated when the valve is in the closed state; and (iv) a solenoid actuator comprising a solenoid coil, an armature, a solenoid spring, and a solenoid sleeve coupled to the armature, where the solenoid sleeve houses the solenoid spring and interfaces therewith, where the solenoid spring applies a biasing force in a distal direction on the pilot pin to seat the pilot pin at the pilot seat, where energizing the solenoid coil causes the armature and the solenoid sleeve coupled thereto to apply a force on the solenoid spring in a proximal direction, thereby reducing the biasing force that the solenoid spring applies on the pilot pin in the distal direction.

In a third example implementation, the present disclosure describes a hydraulic system including: a source of pressurized fluid; a reservoir; a hydraulic actuator having a first chamber and a second chamber; a directional control valve configured to direct fluid flow from the source of pressurized fluid to the first chamber of the hydraulic actuator; and a valve configured to control fluid flow from the second chamber. The valve includes (i) a housing having a pilot port on an exterior peripheral surface of the housing, where the pilot port is fluidly coupled to the first chamber of the hydraulic actuator; (ii) a main stage comprising: (a) a main sleeve defining a first port and a second port, where the first port includes at least one cross hole disposed on an exterior peripheral surface of the main sleeve, and where the second port is defined at a nose of the main sleeve, where the first port is fluidly coupled to the second chamber, and where the second port is fluidly coupled to the reservoir, and (b) a piston axially movable within the main sleeve, where the piston defines a cavity therein, and where the main sleeve defines a piston seat at which the piston is seated when the valve is in a closed state; (iii) a pilot stage comprising a pilot pin received at, and axially movable in, the cavity of the piston, where the piston forms a pilot seat at which the pilot pin is seated when the valve is in the closed state, where the pilot pin is subjected to pressurized fluid received at the first port and subjected to a pilot pressure fluid signal received at the pilot port; and (iv) a solenoid actuator comprising a solenoid coil, an armature, a solenoid spring, and a solenoid sleeve coupled to the armature and configured to house the solenoid spring, where the solenoid spring applies a biasing force in a distal direction on the pilot pin to seat the pilot pin at the pilot seat, where energizing the solenoid coil causes the armature and the solenoid sleeve coupled thereto to apply a force on the solenoid spring in a proximal direction, thereby reducing the biasing force that the solenoid spring applies on the pilot pin.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, implementations, and features described above, further aspects, implementations, and features will become apparent by reference to the figures and the following detailed description.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a hydraulic circuit, in accordance with an example implementation.

FIG. 2 illustrates a cross-sectional side view of a valve in a closed position, in accordance with an example implementation.

FIG. 3 illustrates a cross-sectional bottom view of the valve shown in FIG. 2 in a closed position, in accordance with another example implementation.

FIG. 4 illustrates a three-dimensional view showing an armature coupled to a sleeve, in accordance with an example implementation.

FIG. 5 illustrates a cross-sectional bottom view of the valve shown in FIG. 2 in a reverse flow mode of operation, in accordance with an example implementation.

FIG. 6 illustrates a pilot pin, in accordance with an example implementation.

FIG. 7 illustrates a zoomed-in partial cross-sectional bottom view of the valve shown in FIG. 3 with a pilot pin displaced axially relative to a piston, in accordance with an example implementation.

FIG. 8 illustrates a cross-sectional bottom view of the valve of FIGS. 2-3 with a piston displaced and the valve in an open state, in accordance with an example implementation.

FIG. 9 illustrates a zoomed-in partial cross-sectional side view of the valve shown in FIG. 8, in accordance with an example implementation.

FIG. 10 illustrates a cross-sectional bottom view of the valve 200 in a pressure relief mode, in accordance with an example implementation.

FIG. 11 illustrates a hydraulic circuit using the valve shown in FIG. 2, in accordance with an example implementation.

FIG. 12 illustrates is a flowchart of a method for controlling a hydraulic circuit, in accordance with an example implementation.

FIG. 13 illustrates is a flowchart of a method for operating a valve, in accordance with an example implementation.

DETAILED DESCRIPTION

A counterbalance valve may have a spring that acts against a movable element (e.g., a spool or a poppet), and the force of the spring determines a pressure setting of the counterbalance valve. The pressure setting is a pressure level that causes the counterbalance valve to open and allow fluid flow therethrough. In examples, the counterbalance valve is configured to have a pressure setting that is higher (e.g., 30% higher) than an expected maximum induced pressure in an actuator controlled by the counterbalance valve.

However, this configuration may render operation of the counterbalance valve energy inefficient. Particularly, the expected maximum induced pressure might not occur in all working conditions, and configuring the counterbalance valve to handle the expected maximum induced pressure may cause a large amount of energy loss.

For instance, an actuator may operate a particular tool that experiences a high load in some cases; however, the actuator may operate another tool that experiences small load in other cases. In the cases where the actuator operates a tool that experiences a small load, having the counterbalance valve with a high pressure setting is inefficient. The hydraulic system provides a high pilot pressure to open the counterbalance valve, and the counterbalance generates a large backpressure thereby causing the system to consume an extra amount of power or energy that could have been avoided if the counterbalance valve has a lower pressure setting.

As another example, an actuator of a mobile machinery may be coupled to the machine at a hinge and as the actuator rotates about the hinge the kinematics of the actuator change, and the load may increase or decrease based on the rotational position of the actuator. In some rotational positions, the load may be large causing a high induced pressure, but in other rotational positions the load may be small causing a low induced pressure.

Configuring the counterbalance valve to handle the large load and high induced pressure renders operation of the hydraulic system inefficient when the load is small. Due to the high pressure setting of the counterbalance valve, a large pilot pressure is provided to open the counterbalance valve and a large backpressure is generated, whereas for the small load a low pilot pressure could have been used. The increased pressure level multiplied by flow through the actuator results in energy loss that could have been avoided if the pressure setting of the counterbalance valve is lowered based on conditions of the hydraulic system.

Therefore, it may be desirable to have a counterbalance valve with a pressure setting that could be varied during operation of the hydraulic system. Such variation could render the hydraulic system more efficient.

FIG. 1 illustrates a hydraulic circuit 100, in accordance with an example implementation. The hydraulic circuit 100 includes a directional control valve 102 configured to control flow to and from an actuator 104. The actuator 104 includes a cylinder 106 and a piston 108 slidably accommodated in the cylinder 106. The piston 108 includes a piston head 110 and a rod 112 extending from the piston head 110 along a central longitudinal axis direction of the cylinder 106. The rod 112 is coupled to a load 114. The piston head 110 divides the inside of the cylinder 106 into a first chamber 116 and a second chamber 118.

In an example operation, the direction control valve 102 directs fluid flow received from a source of pressurized fluid, such as a pump 120, to the second chamber 118 to lower the load 114, where the load 114 is a negative load that acts with gravity. Thus, the weight of the load 114 may force fluid out of the first chamber 116 causing the load to drop uncontrollably. Further, flow from the pump 120 might not be able to keep up with movement of the piston 108, causing cavitation in the second chamber 118.

To avoid uncontrollable lowering of the load 114 and cavitation in the second chamber 118, a counterbalance valve 122 is installed in a hydraulic line 123 leading from the first chamber 116 to the directional control valve 102. The counterbalance valve 122 is configured to control or restrict fluid forced out of the first chamber 116. Fluid exiting the counterbalance valve 122 then flows through the direction control valve 102 to a reservoir or tank 124.

A pilot line 126 tapped from a hydraulic line 128 connecting the directional control valve 102 to the actuator 104 is fluidly coupled to a pilot port of the counterbalance valve 122. A pilot pressure fluid signal received through the pilot line 126 acts together with the pressure induced in the first chamber 116 and the hydraulic line 123 due to the load 114, against a force generated by a setting spring 130 of the counterbalance valve 122. The combined action of the pilot pressure fluid signal and the induced pressure in the first chamber 116 facilitates opening the counterbalance valve 122 to allow flow therethrough.

The counterbalance valve 122 is characterized by a ratio between a first differential surface area on which the pilot pressure fluid signal acts and a second differential surface area on which the pressure induced by the load 114 acts within the counterbalance valve 122. Such ratio may be referred to as “pilot ratio.”

Because the pilot pressure fluid signal acts against the setting spring 130, the pilot pressure fluid signal effectively reduces the pressure setting determined by a spring rate of the setting spring 130. The extent of reduction in the pressure setting is determined by the pilot ratio. For example, if the pilot ratio is 3 to 1 (3:1), then for each 10 bar increase in pressure level of the pilot pressure fluid signal, the pressure setting of the setting spring 130 is reduced by 30 bar. As another example, if the pilot ratio is 8 to 1 (8:1), then for each 10 bar increase in the pressure level of pilot pressure fluid signal, the pressure setting of the setting spring 130 is reduced by 80 bar.

If the piston 108 tends to increase its speed, pressure level in the second chamber 118, the hydraulic line 128, and the pilot line 126 may decrease. As a result, the counterbalance valve 122 restricts fluid flow therethrough to preclude the load 114 from dropping at large speeds (i.e., precludes the load 114 and the actuator 104 from overrunning).

Although the hydraulic circuit 100 depicts one counterbalance valve 122, in other examples, the hydraulic circuit 100 may include a second counterbalance valve configured to control fluid flow forced out of the second chamber 118 when the piston 108 extends. In these examples, the counterbalance valve 122 may be configured to allow fluid flow through a reverse-flow check valve 132 from the directional control valve 102 to the first chamber 116. The second counterbalance valve and associated hydraulic line connections are not shown in FIG. 1 to reduce visual clutter in the drawings.

The pressure setting determined by the spring rate of the setting spring 130 is selected such that the counterbalance valve 122 is configured to hold a maximum expected load. For example, if a diameter of the piston head 110 is 40 millimeter (mm) and a diameter of the rod 112 is 28 mm, then an annular area of the piston 108 (e.g., surface area of the piston head 110 minus a cross-sectional area of the rod 112) is equal to 640.56 millimeter squared. Thus, for an example maximum value of the load 114 being 10 kilo Newton (kN), the maximum induced pressure in the first chamber 116 can be estimated as the maximum force divided by the annular area and is thus equal to about 156 bar.

The setting spring 130 is selected to cause the counterbalance valve 122 to have a pressure setting that is higher than the maximum induced pressure so as to be able to hold the load 114. For example, the setting spring 130 may be selected to cause the counterbalance valve 122 to have a pressure setting of 210 bar.

As such, to open the counterbalance valve 122 and allow flow therethrough, the pilot pressure fluid signal and the induced pressure in the second chamber 118 apply respective forces within the counterbalance valve 122 that overcome the force caused by the setting spring 130. This configuration may render the hydraulic circuit 100 inefficient.

Particularly, in some cases, the load 114 might not be an overrunning load (i.e., the load 114 may be a positive load), and thus the induced pressure in the second chamber 118 may be low. In these cases, to open the counterbalance valve 122, a high pilot pressure is generated in the hydraulic line 128 and is tapped therefrom to be communicated through the pilot line 126 to the pilot port of the counterbalance valve 122. In other words, the pressure level in the hydraulic line 128 rises to provide the high pilot pressure to open the counterbalance valve when the load 114 is not an overrunning load. If the pressure setting determined by the setting spring 130 is lower, then a lower pilot pressure could have opened the counterbalance valve 122.

Fluid power is estimated by a multiplication of pressure level and flow rate through the hydraulic system. Thus, if pressure level is decreased, then the power that the pump 120 consumes to generate the fluid having sufficient power to operate the actuator 104 is also decreased and the hydraulic circuit 100 may operate more efficiently.

Therefore, it may be desirable to configure the counterbalance valve 122 such that the pressure setting of the setting spring 130 can be adjusted during operation of the hydraulic circuit 100. For example, an electronic controller of the hydraulic circuit 100 may be in communication with pressure sensors or load sensors coupled to the actuator 104. The controller may then adjust the pressure setting based on sensor information indicating the pressure level in the first chamber 116 or indicating the magnitude of the load 114. Thus, for positive loads and low pressure levels in the first chamber 116, the pressure setting could be reduced to render the hydraulic circuit 100 more efficient. The controller may continually adjust the pressure setting of the setting spring 130 during operation of the hydraulic circuit 100 based on the sensor information.

Further, changing pressure setting based on load conditions may enhance stability of the counterbalance valve 122. Enhanced stability of the counterbalance valve 122 indicates fewer oscillations in movable elements of the counterbalance valve 122, and thus fewer oscillations in inlet, pilot, and outlet pressure levels of the counterbalance valve 122. The stability of the counterbalance valve 122 may be based on several factors including the pressure setting, the pilot ratio, and the capacity of the counterbalance valve 122. In examples, a lower pressure setting may enhance stability of the counterbalance valve 122. Also, in examples, a lower pilot ratio may enhance stability of the counterbalance valve 122. Similarly, in examples, a lower capacity (smaller flow rate through the counterbalance valve 122) for a given pilot ratio may enhance stability of the counterbalance valve 122.

Disclosed herein is a counterbalance and relief valve that is configured to have an adjustable pressure setting and having enhanced stability.

FIG. 2 illustrates a cross-sectional side view of a valve 200 in a closed position, and FIG. 3 illustrates a cross-sectional bottom view of the valve 200 in the closed position, in accordance with an example implementation. The valve 200 may be inserted or screwed into a manifold having ports corresponding to ports of the valve 200 described below, and may thus fluidly couple the valve 200 to other components of a hydraulic system.

The valve 200 may include a main stage 202, a pilot stage 204, and a solenoid actuator 206. The valve 200 includes a housing 208 that defines a longitudinal cylindrical cavity therein. The longitudinal cylindrical cavity of the housing 208 is configured to house portions of the main stage 202, the pilot stage 204, and the solenoid actuator 206.

The main stage 202 includes a main sleeve 210 received at a distal or first end of the housing 208, and the main sleeve 210 is coaxial with the housing 208. The main sleeve 210 defines a first port 212 and a second port 214. The second port 214 is defined at a nose of the main sleeve 210 and can be referred to as a tank port or exhaust port, for example. The first port 212 may include a set of cross holes such as cross holes 215A, 215B (shown in FIG. 3) disposed in a radial array about an exterior surface of the main sleeve 210. In examples, the first port 212 could be referred to as a load port. The term “hole” is used herein to indicate a hollow place in a solid body or surface, for example.

As shown in FIG. 2, the main sleeve 210 includes or defines longitudinal channels 216A, 216B and slanted channel 218A, 218B (e.g., configured as angled cross holes). The main sleeve 210 further defines an annular groove 220 on an exterior peripheral surface of the main sleeve 210. The term “groove” is used herein to indicate a cut or a depression in a surface, for example. With this configuration, fluid at the second port 214 is communicated through the longitudinal channels 216A, 216B and the slanted channel 218A, 218B to the annular groove 220.

The valve 200 includes a piston 224 disposed, and slidably accommodated, in the cavity of the main sleeve 210. An interior peripheral surface of the main sleeve 210 forms a piston seat 222 for the piston 224. In the closed position shown in FIGS. 2-3, the piston 224 is seated on the piston seat 222. The piston 224 can also be referred to as a main piston or main poppet.

The piston 224 defines a cavity 225 therein configured as a longitudinal blind hole that receives a distal end of a pilot pin 226. The pilot pin 226 is slidably accommodated within the cavity 225 of the piston 224 and is configured to be seated at a pilot seat 228 formed on an interior surface of the piston 224 at a proximal end of the piston 224.

The valve 200 further includes a roll pin 221 coupled to a check ball 223 (e.g., a metal sphere) that operates as a check valve. The roll pin 221 and the check ball 223 are disposed within the piston 224 at a nose section or a distal end of the piston 224. The check ball 223 blocks a longitudinal passage or longitudinal channel 227 defined in the distal end of the piston 224, and thus the check ball 223 blocks or restricts fluid flow from the second port 214 through the nose section of the piston 224 and the longitudinal channel 227 to the cavity 225. However, if pressurized fluid is provided to the cavity 225, the pressurized fluid in the cavity 225 can flow through the longitudinal channel 227, push the check ball 223 and the roll pin 221, and flow to the second port 214.

Referring to FIG. 3, the piston 224 includes or defines a longitudinal channel 229 and a pilot feed orifice 230. The longitudinal channel 229 is configured as a longitudinal blind hole that does not extend throughout the length of the piston 224. In operation, the first port 212 may be fluidly coupled to a source of pressurized fluid (e.g., a pump or accumulator). The pressurized fluid received at the first port 212 is communicated through unsealed spaces between an interior surface of the main sleeve 210 and the exterior surface of the piston 224, and through the pilot feed orifice 230, to a chamber 238. As such, the chamber 238 is fluidly coupled to the first port 212 via the pilot feed orifice 230 and the longitudinal channel 229.

In examples, a portion of the piston 224 axially between the pilot feed orifice 230 and the cross holes 215A, 215B may have a first outside diameter. Another portion of the piston 224 axially between the pilot feed orifice 230 and the proximal end of the piston 224 may have a second outside diameter. The first outside diameter can be made slightly smaller than the second outside diameter. In these examples, a clearance between an exterior peripheral surface of the piston 224 and an interior peripheral surface of the main sleeve 210 can vary along a length of the piston 224. Particularly, the clearance can be larger (e.g., by an order of magnitude) at the portion of the piston 224 between the pilot feed orifice 230 and the distal end of the piston 224 than the clearance at the portion of the piston 224 between the pilot feed orifice 230 and the proximal end of the piston 224.

As an example for illustration, the clearance at the portion of the piston 224 between the pilot feed orifice 230 and the distal end of the piston 224 can be about 0.001-0.004 inches, whereas the clearance at the portion of the piston 224 between the pilot feed orifice 230 and the proximal end of the piston 224 can be a few 0.0001 inches (e.g., 0.0003 inches). This way, the clearance at the portion of the piston 224 between the pilot feed orifice 230 and the distal end of the piston 224 can operate as a gap filter between the piston 224 and the main sleeve 210. Such gap filter can preclude any impurities contaminants in the fluid from passing from the first port 212 to the pilot feed orifice 230, and thereby preclude blocking the pilot feed orifice 230 with impurities.

Referring back to FIG. 2, the valve 200 includes two spacers disposed in the longitudinal cavity of the housing 208 axially adjacent to the piston 224. A first spacer 232 is ring-shaped and is disposed within the main sleeve 210. A second spacer 234 is also ring-shaped adjacent to and abuts the first spacer 232. The second spacer 234 is disposed partially within the longitudinal cavity of the main sleeve 210 and partially within the longitudinal cavity of the housing 208. The pilot pin 226 is disposed through the two spacers 232 and 234. In other words, the spacers 232, 234 form a channel bound by the interior peripheral surfaces of the spacers 232 and 234, and the pilot pin 226 is disposed through the channel. The first spacer 232 is secured against a protrusion 236 formed on an interior peripheral surface of the main sleeve 210, and the first spacer 232 is separated from the piston 224 via the chamber 238.

The housing 208 forms a protrusion 242 from an interior peripheral surface of the housing 208 to form a hole or channel through which the pilot pin 226 is disposed. The spacers 232, 234 are thus disposed between the protrusion 236 and the protrusion 242.

The housing 208 further defines a pilot port 244 on an exterior peripheral surface of the housing 208. Cross holes such as cross hole 246 shown in FIG. 3 are disposed in the housing 208 and configured to communicate a pilot pressure fluid signal received at the pilot port 244 to an annular groove 247 defined on the exterior peripheral surface of the second spacer 234. Further, as shown in FIG. 2, slanted channels such as a slanted channel 248 disposed in the second spacer 234 then communicate the pilot pressure fluid signal from the annular groove 247 to an annular space 250 formed between an interior peripheral surface of the second spacer 234 and the exterior peripheral surface of the pilot pin 226.

Referring to FIG. 2, the annular groove 220 of the main sleeve 210 is fluidly coupled to an axial gap 241 formed between a proximal end of the main sleeve 210 and a shoulder formed on the exterior surface of the second spacer 234. Referring now to FIG. 3, the second spacer 234 has cross holes such as cross hole 243 that fluidly couples the axial gap 241 to a longitudinal channel 245 formed in the second spacer 234. The longitudinal channel 245 is configured as a longitudinal blind hole that does not extend throughout the length of the second spacer 234. The longitudinal channel 245 then communicates fluid received through the cross hole 243 to a groove 249 formed in the second spacer 234.

The groove 249 of the second spacer 234 extends across a bottom or proximal end face of the second spacer 234. The groove 249 can be configured such that the longitudinal channel 245 communicates fluid to the groove 249. The rest of the proximal end face of the second spacer 234 rests is flush with the protrusion 242 as depicted in FIG. 2. With this configuration, fluid is communicated from the second port 214 to the proximal end face of the second spacer 234.

Referring back to FIG. 2, the solenoid actuator 206 includes a solenoid tube 252 configured as a cylindrical housing disposed within and received at the proximal end of the housing 208, such that the solenoid tube 252 is coaxial with the housing 208. A solenoid coil 254 is disposed about an exterior surface of the solenoid tube 252.

The solenoid tube 252 is configured to house an armature 256. The armature 256 defines therein a longitudinal channel through which a solenoid pin 258 is disposed. The solenoid pin 258 is slidably accommodated within the armature 256, and the armature 256 and the solenoid pin 258 are configured to move axially relative to each other.

A distal end of the solenoid pin 258 is coupled to a first or proximal spring cap 260 disposed against and supporting a proximal end of a solenoid spring 262. A distal end of the solenoid spring 262 is secured against a second or distal spring cap 264.

The solenoid actuator 206 further includes a solenoid sleeve 266 received at the proximal end of the housing 208 and also disposed partially within a distal end of the solenoid tube 252. The solenoid sleeve 266 has a protrusion 268 at a distal end of the solenoid sleeve 266. The distal spring cap 264 has a flanged portion 270 that interfaces with and rests against the protrusion 268 of the solenoid sleeve 266 when the valve 200 is in the closed position shown in FIGS. 2-3.

The armature 256 is coupled to the solenoid sleeve 266. As such, if the armature 256 moves axially (e.g., in the proximal direction), the solenoid sleeve 266 moves along with the armature 256 in the same direction. The armature 256 can be coupled to the solenoid sleeve 266 in several ways. FIG. 4 illustrates a three-dimensional view showing the armature 256 coupled to the solenoid sleeve 266, in accordance with an example implementation. As shown, the solenoid sleeve 266 may have a male T-slot 272, and the armature 256 may have a corresponding female T-slot configured to receive the male T-slot of the solenoid sleeve 266. With this configuration, the armature 256 and the solenoid sleeve 266 are coupled to each other, such that if the armature 256 moves, the solenoid sleeve 266 moves therewith. The configuration shown in FIG. 4 is an example for illustration only, and other fastening configurations could be used to couple the solenoid sleeve 266 to the armature 256.

Referring back to FIG. 2, the solenoid tube 252 includes a pole piece 274 separated from the armature 256 by an airgap 276. The pole piece 274 may be composed of material of high magnetic permeability. The pole piece 274 is shown in FIG. 2 as an integral part of the solenoid tube 252. In other example implementations, however, the pole piece could be a separate component.

The pole piece 274 defines therein a channel through which the solenoid pin 258 is disposed. While a distal end of the solenoid pin 258 is coupled to the proximal spring cap 260, a proximal end of the solenoid pin 258 is coupled to a plunger or plug 278 that interfaces with a set screw 280 disposed at a proximal end of the valve 200. Once the set screw 280 is screwed into the valve 200 to a particular axial position, the set screw 280 and the plug 278 assume a particular fixed axial position. As a result, the solenoid pin 258 and the proximal spring cap 260 coupled thereto also assume a fixed axial position. With this configuration, the proximal end of the solenoid spring 262 resting against the proximal spring cap 260 is fixed, whereas the distal end of the solenoid spring 262 resting against the distal spring cap 264 is movable and biases the distal spring cap 264 and the solenoid sleeve 266 in the distal direction. As such, the solenoid spring 262 applies a biasing or preload force on the distal spring cap 264.

As described above, a distal end of the pilot pin 226 is received within the piston 224, whereas a proximal end of the pilot pin 226 interfaces with the distal spring cap 264. As the solenoid spring 262 applies the biasing force to the distal spring cap 264, the force is transferred to the pilot pin 226. With this configuration, the solenoid spring 262 applies the biasing or preload force on the pilot pin 226, thus causing the pilot pin 226 to be seated at the pilot seat 228 of the piston 224, and thereby biasing the piston 224 to be seated at the piston seat 222.

The biasing force of the solenoid spring 262 determines the pressure setting of the valve 200 as described below with respect to FIG. 6. The solenoid spring 262 can thus be referred to as the setting spring.

The set screw 280 is configured as a mechanical or manual adjusting the maximum pressure setting of the valve 200. For example, if the set screw 280 is rotated in a first direction (e.g., in a clockwise direction), the set screw 280 may move axially in the distal direction (e.g., to the right in FIG. 2) pushing the plug 278 and the solenoid pin 258 in the distal direction. The solenoid pin 258 in turn pushes the proximal spring cap 260 in the distal direction, thus compressing the solenoid spring 262 and increasing the preload or biasing force of the solenoid spring 262.

Conversely, rotating the set screw 280 in a second direction (e.g., counter-clockwise) causes the set screw 280 to move axially in the proximal direction, allowing the solenoid spring 262 to push the proximal spring cap 260, the solenoid pin 258, and the plug 278 in the proximal direction. The length of the solenoid spring 262 thus increases and the preload or biasing force of the solenoid spring 262 is reduced. With this configuration, the biasing force of the solenoid spring 262, and thus the pressure setting of the valve 200, can be adjusted via the set screw 280.

The valve 200 is configured to operate in different modes of operation. For example, the valve 200 may be used as a counterbalance valve, such as the counterbalance valve 122. In this example, the valve 200 may be installed in the hydraulic circuit 100 such that the first port 212 of the valve 200 is fluidly coupled to the first chamber 116, the second port 214 is fluidly coupled to the directional control valve 102, and the pilot port 244 is coupled to the pilot line 126. As such, the valve 200 is configured to allow reverse flow from the second port 214 to the first port 212 to perform the operation of the reverse-flow check valve 132 described above with respect to FIG. 1.

FIG. 5 illustrates a cross-sectional bottom view of the valve 200 in a reverse flow mode of operation, in accordance with an example implementation. In the reverse flow mode of operation, pressurized fluid is received at the second port 214 (e.g., from the directional control valve 102), and the valve 200 allows fluid to flow from the second port 214 to the first port 212.

The pressurized fluid received at the second port 214 applies a force on a portion of a distal end face of the piston 224. For example, the pressurized fluid at the second port 214 applies a force on a surface area substantially equal to a circular area having a diameter “d” of the piston seat 222 depicted in FIG. 3. If the force of the pressurized fluid at the second port 214 overcomes the force applied by the solenoid spring 262 on the piston 224 via the distal spring cap 264 and the pilot pin 226, the piston 224 is unseated off the piston seat 222 (e.g., the piston 224 moves to the left as shown in FIG. 5 relative to FIGS. 2-3). As a result, an annular flow area 282 forms between the exterior surface of the piston 224 and the interior surface of the main sleeve 210. Pressurized fluid then flows freely (e.g., without sending a signal to the solenoid coil 254 and without a pilot pressure fluid signal to the pilot port 244) from the second port 214 through the annular flow area 282 and the cross holes 215A, 215B to the first port 212. From the first port 212, the pressurized fluid can flow, for example, to the first chamber 116.

As an example for illustration, the diameter “d” could be about 0.25 inches. Thus, the circular area on which the pressurized fluid at the second port 214 applies a force can be determined as

$\frac{π}{4} (d^{2}) = 0.05$

square inches. Assuming that the solenoid spring 262 apples a force of 10 pound-force (lbf) on the piston 224, then a pressure level at the second port 214 that would cause the force applied by the pressurized fluid at the second port 214 to overcome the force of the solenoid spring 262 can be determined as

$\frac{10}{0.05} = 200$

pounds per square inches (psi). Thus, once the pressure level at the second port 214 exceeds the pressure level at the first port 212 by 200 psi, the piston 224 may be unseated, and fluid is allowed to flow from the second port 214 to the first port 212. These numerical values are provided herein as examples for illustration only and are not limiting.

With this configuration, the valve 200 allows for reverse flow from the second port 214 to the first port 212 without a separate reverse flow piston. This way, the valve 200 can have less weight and cost relative to other counterbalance valves that include a separate reverse flow piston to allow for reverse flow.

As mentioned above with respect to FIG. 1, when the load 114 acts with gravity (e.g., overrunning load) the counterbalance valve 122 facilitates lowering the load 114 controllably by restricting flow of fluid forced out of the first chamber 116. Particularly, the counterbalance valve 122 receives a pilot pressure fluid signal from the pilot line 126 that acts along with the fluid received from the first chamber 116 to open the counterbalance valve 122. The counterbalance valve 122 prevents fluid flow from the first chamber 116 through the counterbalance valve 122 until the combined force of the pilot pressure fluid signal and the fluid from the first chamber 116 overcomes the biasing force of the setting spring 130. The amount of flow allowed through the counterbalance valve 122 is based on the pressure level of the pilot pressure fluid signal in the pilot line 126, such that a higher pilot pressure fluid signal causes the counterbalance valve 122 to allow a large amount of flow. This mode of operation can be referred to as the pilot modulation mode of operation.

The valve 200 is configured to operate in the pilot modulation mode of operation as well. Particularly, when a pilot pressure fluid signal received at the pilot port 244 along with the fluid received at the first port 212 act on the pilot pin 226 and overcome the pressure setting of the valve 200, the valve 200 opens and fluid is allowed from the first port 212 to the second port 214.

As mentioned above, pressurized fluid received at the first port 212 is communicated to the chamber 238 via the pilot feed orifice 230 and the longitudinal channel 229. The pressurized fluid applies forces on external surfaces of the pilot pin 226.

Further, the pilot pressure fluid signal received at the pilot port 244 is communicated to the annular space 250 via the cross hole 246 and the channel 248 and applies respective forces on respective external surfaces of the pilot pin 226. The forces from both the pressurized fluid received at the first port 212 and the pilot pressure fluid signal act on the pilot pin 226 in the proximal direction (also referred to as the opening direction) due to the configuration of the pilot pin 226 as described below with respect to FIG. 6.

Further, fluid at the second port 214 is communicated via the longitudinal channels 216A, 216B and the slanted channel 218A, 218B of the main sleeve 210 to the annular groove 220. From the annular groove 220, fluid is communicated to the groove 249 via the axial gap 241, the cross hole 243, and the longitudinal channel 245. The fluid from the second port 214 may apply respective forces on respective external surfaces of the pilot pin 226. The forces of the fluid received at the second port 214 acts on the pilot pin 226 in the distal direction (also referred to as the closing direction) due to the configuration of the pilot pin 226 as described next with respect to FIG. 6.

FIG. 6 illustrates the pilot pin 226, in accordance with an example implementation. As depicted in FIG. 6, the pilot pin 226 is configured to have a plurality of lands alternating with reduced diameter regions to form annular grooves on an exterior peripheral surface of the pilot pin 226. The pilot pin 226 has a seating edge 284 (circled in FIG. 6) that interfaces with the pilot seat 228 formed in the piston 224 when the valve 200 is in the closed position. The pilot pin 226 has a distal land 285 that is disposed within the cavity 225 of the piston 224. The space between the exterior peripheral surface of the distal land 285 and an interior peripheral surface of the cavity 225 is unsealed, and in examples a diameter of the distal land 285 may be slightly smaller than an interior diameter of the cavity 225 such that fluid is allowed to flow therebetween as described below.

The pilot pin further has a first annular groove 286, a second annular groove 288, a third annular groove 289, and a plurality of balancing grooves 290. During operation of the valve 200, the balancing grooves 290 facilitate axial motion of the pilot pin 226 within the second spacer 234.

The first annular groove 286 is disposed in the chamber 238 when the valve 200 is in the closed position shown in FIG. 2. As such, the pressurized fluid received at the first port 212 and communicated to the chamber 238 via the pilot feed orifice 230 and the longitudinal channel 229 (see FIG. 3) is provided to the first annular groove 286.

The first annular groove 286 is bounded by a first annular surface area “A₁” and a second annular surface area “A₂” labelled in FIG. 6. The annular surface areas “A₁” and “A₂” are ring-shaped. The pressurized fluid provided to the first annular groove 286 applies respective forces in opposite directions on the annular surfaces areas “A₁” and “A₂” The annular surface area “A₁” is larger than the annular surface area “A₂.” Specifically, the difference A₁minus A₂can be determined as

$\frac{π}{4} (d_{1}^{2} - d_{2}^{2}),$

where “d₁” and “d₂” are labelled in FIG. 6. The difference A₁minus A₂can be referred to as effective or differential relief area A_DR. The pressure setting of the valve 200 can be determined by dividing the biasing force that the solenoid spring 262 applies to the pilot pin 226 (via the distal spring cap 264) by the differential relief area A_DR.

As a result, the pressurized fluid in the chamber 238 applies a net force on the pilot pin 226 in the proximal direction (e.g., to the left in FIGS. 2 and 6). The net force can be determined, for example, by multiplying a pressure level of the pressurized fluid by the area difference A₁minus A₂. This net force might not be sufficiently large to overcome the pressure setting of the valve 200 (e.g., overcome the force of the solenoid spring 262 on the pilot pin 226 via the distal spring cap 264). This net force is, however, supplemented by a force applied to the pilot pin 226 by the pilot pressure fluid signal received at the pilot port 244.

The pilot pressure fluid signal received at the pilot port 244 and communicated to the annular space 250 via the cross hole 246 and the channel 248 is provided to the second annular groove 288 of the pilot pin 226. The second annular groove 288 is bounded by a third annular surface area “A₃” and a fourth annular surface area “A₄” labelled in FIG. 6. The annular surface areas “A₃” and “A₄” are ring-shaped. The pilot pressure fluid signal communicated to the second annular groove 288 applies respective forces in opposite directions on the annular surfaces areas “A₃” and “A₄” The annular surface area “A₄” is larger than the annular surface area “A₃.” Specifically, the difference A₄minus A₃can be determined as

$\frac{π}{4} (d_{3}^{2} - d_{1}^{2}),$

where “d₃” and “d₁” are labelled in FIG. 6. The difference A₄minus A₃can be referred to as effective or differential pilot area A_DP.

As a result, the pilot pressure fluid signal applies a net force on the pilot pin 226 in the proximal direction (e.g., to the left in FIGS. 2 and 6). The net force can be determined, for example, by multiplying a pressure level of the pilot pressure fluid signal by the differential area A_DP.

Further, the fluid received at the second port 214 and communicated to the groove 249 is provided to the third annular groove 289 of the pilot pin 226. The third annular groove 289 is bounded by a fifth annular surface area “A₅” and a sixth annular surface area “A₆” labelled in FIG. 6. The annular surface areas “A₅” and “A₆” are ring-shaped. The fluid communicated to the third annular groove 289 applies respective forces in opposite directions on the annular surfaces areas “A₅” and “A₆” The annular surface area “A₆” is larger than the annular surface area “A₅.” Specifically, the difference A₆minus A₅can be determined as

$\frac{π}{4} (d_{3}^{2} - d_{4}^{2}),$

where “d₃” and “d₄” are labelled in FIG. 6. As a result, the fluid from the second port 214 applies a net force on the pilot pin 226 in the distal direction (e.g., to the right in FIGS. 2 and 6). The net force can be determined, for example, by multiplying a pressure level of the fluid received at the second port 214 by the difference A₆minus A₅.

The net force applied by the fluid from the second port 214 on the pilot pin 226 in the distal direction operate as a reference force against which the forces applied by the pressurized fluid from the first port 212 and the pilot pressure fluid signal received from the pilot port 244 act in the proximal direction. In examples, when the valve 200 operates in the pilot modulation mode, the pressure level of the fluid at the second port 214 is low (e.g., 0-70 psi) and therefore the force that such fluid applies on the pilot pin 226 may be negligible.

As such, several forces are applied to the pilot pin 226. The solenoid spring 262 applies a first force on the pilot pin 226 via the distal spring cap 264 in the distal direction. The fluid from the second port 214 applies a second force on the pilot pin 226 in the distal direction as well. On the other hand, the pressurized fluid at the first port 212 applies a third force on the pilot pin 226 in the proximal direction, and the pilot pressure fluid signal applies a fourth force on the pilot pin 226 also in the proximal direction. When the pressure levels of the pressurized fluid at the first port 212 and the pilot pressure fluid signal are sufficiently high to cause the third and fourth forces acting in the proximal direction to overcome the first force of the solenoid spring 262 and the second force of the fluid from the second port 214 acting in the distal direction, the pilot pin 226 is pushed or displaced axially in the proximal direction. As such, the pilot pin 226 is unseated off the pilot seat 228 formed in the piston 224.

As the pilot pin 226 moves axially in the proximal direction relative to the piston 224 and the spacers 232 and 234, the pilot pin 226 pushes the distal spring cap 264 in the proximal direction, thereby compressing the solenoid spring 262. As a result of compression of the solenoid spring 262, the first force that the solenoid spring 262 applies on the pilot pin 226 in the distal direction increases. Thus, the pilot pin 226 may move axially in the proximal direction until force equilibrium between the third and fourth forces on one hand, and the increased first force and the second force on the other hand is reached.

FIG. 7 illustrates a zoomed-in partial cross-sectional bottom view of the valve 200 with the pilot pin 226 displaced axially relative to the piston 224, in accordance with an example implementation. As mentioned above, fluid at the first port 212 is communicated through the cross holes 215A, 215B, the pilot feed orifice 230, and the longitudinal channel 229 to the chamber 238. As a result of the pilot pin 226 being unseated off the pilot seat 228, a flow area 291 is formed between the exterior surface of the pilot pin 226 and the interior surface of the piston 224. Thus, fluid in the chamber 238 flows through the flow area 291, around the distal land 285 of the pilot pin 226 to the longitudinal channel 227. Then, the fluid pushes the check ball 223 and the roll pin 221 as depicted in FIG. 7 to flow to the second port 214. The fluid flow from the first port 212 through the pilot feed orifice 230, the longitudinal channel 229, the flow area 291, and the longitudinal channel 227 to the second port 214 can be referred to as the pilot flow.

The pilot flow through the pilot feed orifice 230 and the longitudinal channel 229 causes a pressure drop in the pressure level of the fluid. Thus, the pressure level of fluid in the chamber 238 becomes lower than the pressure level of fluid received at the first port 212. As a result, the fluid at the first port 212 applies a force on annular surface areas 292 and 293 of the piston 224 in the proximal direction (e.g., to the left in FIG. 7) that is larger than the force applied by fluid in the chamber 238 on back end surface 294 of the piston 224 in the distal direction (e.g., to the right in FIG. 7). Due to such force imbalance on the piston 224, a net force is applied to the piston 224 in the proximal direction, causing the piston 224 to move or be displaced axially in the proximal direction.

FIG. 8 illustrates a cross-sectional bottom view of the valve 200 with the piston 224 displaced and the valve 200 in an open state, and FIG. 9 illustrates a zoomed-in partial cross-sectional side view of the valve 200 as shown in FIG. 8, in accordance with an example implementation. The net force acting on the piston 224 in the proximal direction causes the piston 224 to be unseated off the piston seat 222 and follow the pilot pin 226, as depicted in FIGS. 8-9. As a result, fluid received at the first port 212 is allowed to flow through the cross holes 215A, 215B and through a flow area 295 formed between the piston 224 and the interior surface of the main sleeve 210 directly to the second port 214, rendering the valve 200 in an open state. The direct flow from the first port 212 to the second port 214 can be referred to as the main flow.

As the pilot pin 226 and the piston 224 move in the proximal direction, the distal spring cap 264 also moves in the proximal direction relative to the protrusion 268 of the solenoid sleeve 266. The extent of motion is shown by comparing the position of the flanged portion 270 of the distal spring cap 264 relative to the protrusion 268 in FIG. 8 with the position of the flanged portion 270 relative to the protrusion 268 in FIG. 2.

The configuration of the valve 200 renders the valve 200 more stable than other valve configurations. As mentioned above, one of the factors that affect stability of a counterbalance valve is the pilot ratio. The pilot ratio determines how the pressure setting of the valve 200 changes as the pilot pressure (i.e., the pressure level of the pilot pressure fluid signal at the pilot port 244) changes. As an example, a 3:1 pilot ratio indicates that an increase of, for example, 10 bar in the pilot pressure decreases the pressure setting by 30 bar.

With the configuration of the valve 200, the pilot ratio is determined based on the areas labelled “A₁,” “A₂,” “A₃,” and “A₄” in FIG. 6. Specifically, the pilot ratio P_Rof the valve 200 can be estimate by the following equation:

$\begin{matrix} P_{R} = \frac{A_{DP}}{A_{DR}} = \frac{A_{4} - A_{3}}{A_{1} - A_{2}} & (1) \end{matrix}$

The pilot pin 226 can be configured such that the areas “A₁,” “A₂,” “A₃,” and “A₄” achieve a particular P_Rthat enhances stability of the valve 200. Notably, the pilot ratio P_Ris independent of the effective area of the pilot seat 228 (e.g., the circular area having a diameter of the pilot seat 228 determined by the piston 224). Thus, the pilot ratio is determined by the configuration of the pilot pin 226, rather than by both the pilot pin 226 and the piston 224.

Further, the pilot pressure fluid signal received at the pilot port 244 applies a force on the pilot pin 226, which is independent and decoupled from the piston 224. Thus, the pilot pressure fluid signal at the pilot port 244 acts on a movable element (the pilot pin 226) different from the main movable element (the piston 224). In other words, the pilot pressure fluid signal does not act or apply a force on the main movable element (the piston 224) that restricts or blocks the main flow path from the first port 212 to the second port 214. This configuration may enhance stability of the valve 200 relative to other counterbalance valves.

Further, the piston 224 is not supported or acted upon by a spring as conventional counterbalance valves are configured where the main movable element is acted upon directly by a spring. The lack of a spring in the valve 200 acting directly on the piston 224 may reduce the likelihood of oscillations of the piston 224 and renders the valve 200 more stable.

Referring back to FIG. 2, beneficially, the valve 200 is characterized in that the pressure setting of the valve 200 can be adjusted based on a signal provided to the solenoid coil 254. When an electric current is provided through the windings of the solenoid coil 254, a magnetic field is generated. The pole piece 274 directs the magnetic field through the airgap 276 toward the armature 256, which is movable and is attracted toward the pole piece 274. As such, a solenoid force is applied on the armature 256, where the solenoid force is a pulling force that tends to pull the armature 256 in the proximal direction.

The solenoid force applied to the armature 256 is also applied to the solenoid sleeve 266 coupled to the armature as described with respect to FIG. 4. The solenoid sleeve 266 in turn applies a force on the distal spring cap 264 in the proximal direction due to the interaction between the protrusion 268 and the flanged portion 270. The distal spring cap 264 in turn applies a compressive force in the proximal direction on the solenoid spring 262. As a result, the biasing force that the solenoid spring 262 applies to the pilot pin 226 in the distal direction is reduced, and the pressure setting of the valve 200 is also reduced.

Such reduction in the pressure setting when the solenoid coil 254 is energized can take place whether the valve 200 is open or closed and whether the armature 256 moves or not. Under some operating conditions, load pressure at the first port 212 and forces acting on the pilot pin 226 allow the distal spring cap 264 to move. Under these operating conditions, when the solenoid coil 254 is energized, and because the pole piece 274 is fixed and the armature 256 is movable, the armature 256 is pulled in the proximal direction and traverses the airgap 276 toward the pole piece 274. The armature 256 moves while the solenoid pin 258 does not move therewith. As the armature 256 is pulled in the proximal direction, the armature 256 causes the solenoid sleeve 266 coupled thereto to move in the proximal direction as well. As the solenoid sleeve 266 moves in the proximal direction, the protrusion 268, which interfaces and interacts with the flanged portion 270, causes the distal spring cap 264 to also move in the proximal direction. The proximal spring cap 260, however, remains stationary as it is coupled to the solenoid pin 258, which does not move with the armature 256.

As a result of the motion of the distal spring cap 264 in the proximal direction, the biasing force that the solenoid spring 262 applies to the pilot pin 226 in the distal direction is reduced. For example, the biasing force acting on the pilot pin 226 can be determined as the spring force of the solenoid spring 262 minus the solenoid force applied by the armature 256 on the solenoid sleeve 266 in the proximal direction. As a result of the reduction in the force applied to the pilot pin 226, the pressure setting of the valve 200 is reduced. Thus, the force that the pressurized fluid received at the first port 212 and the pilot pressure fluid signal received the pilot port 244 need to apply on the pilot pin 226 to open the valve 200 is reduced.

When the valve 200 is closed or the operating conditions (load pressure at the first port 212 and forces acting on the pilot pin 226) do not allow the distal spring cap 264 to move, pressure setting of the valve 200 is determined by a static force balance between forces acting on the pilot pin 226. Under static conditions, the solenoid force applied to the armature 256 is transferred to solenoid spring 262 via the solenoid sleeve 266 and the distal spring cap 264. As a result of the force applied on the solenoid spring 262 in the proximal direction, a reduction in the pressure setting of the valve 200 takes place despite absence of motion of the armature 256, the solenoid sleeve 266, or the distal spring cap 264.

With this configuration, the pulling force (e.g., the solenoid force) of the armature 256 in the proximal direction and the force that the pilot pressure fluid signal applies to the pilot pin 226 assist the pressurized fluid received at the first port 212 in overcoming the force applied to the pilot pin 226 in the distal direction by the solenoid spring 262 and the fluid in the groove 249 (see FIG. 3). In other words, the force that the pressurized fluid received at the first port 212 needs to apply to the pilot pin 226 to cause it to move axially in the proximal direction is reduced to a predetermined force value that is based on: (i) the pressure level of the pilot pressure fluid signal, and (ii) the solenoid force that is based on the magnitude of the electric current (e.g., magnitude of the signal) provided to the solenoid coil 254. As such, the pulling force (i.e., the solenoid force) resulting from sending a signal to the solenoid coil 254 and the force resulting from the pilot pressure fluid signal received at the pilot port 244 effectively reduce the pressure setting of the valve 200, and thus a reduced pressure level at the first port 212 can cause the valve 200 to open.

The valve 200 could operate in other modes of operation as well. For instance, in addition to being configured as a counterbalance valve, the valve 200 could be configured as a pressure relief valve.

FIG. 10 illustrates a cross-sectional bottom view of the valve 200 in a pressure relief mode, in accordance with an example implementation. In the pressure relief mode, the valve 200 could be used to control or limit pressure level in a hydraulic system. The valve 200 is configured to open when pressure level of fluid received at the first port 212 and communicated to the chamber 238 reaches a predetermined set pressure determined by the solenoid spring 262. The predetermined set pressure is determined by dividing a preload force that the solenoid spring 262 applies to the pilot pin 226 (via the distal spring cap 264) by the differential relief area A_DRdefined above with respect to FIG. 6.

As mentioned above with respect to FIG. 6, the first annular groove 286 of the pilot pin 226 is disposed in the chamber 238 when the valve 200 is in the closed position shown in FIG. 2. As such, the pressurized fluid in the chamber 238 is communicated to the first annular groove 286 of the pilot pin 226 and applies a net force in the proximal direction on the pilot pin 226 due to the area difference between “A₁” and “A₂.” The fluid at the second port 214 is communicated to the groove 249 as described above and is communicated to the third annular groove 289 (see FIG. 6). The fluid in the groove 249 applies a net force in the distal direction on the pilot pin 226 due to the area difference between “A₅” and “A₅.”

Once the net force applied on the pilot pin 226 in the proximal direction by the pressurized fluid in the chamber 238 exceeds the forces applied by the solenoid spring 262 and the fluid in the groove 249 on the pilot pin 226 in the distal direction, the pilot pin 226 moves axially in the proximal direction off the pilot seat 228.

As a result of the pilot pin 226 being unseated, a pilot flow is generated from the first port 212 through pilot feed orifice 230 and the longitudinal channel 229 to the chamber 238, then around the pilot pin 226 (e.g., through a flow area similar to the flow area 291 shown in FIG. 7) and the longitudinal channel 227 and around the check ball 223 and the roll pin 221 to the second port 214. The pilot flow from the first port 212 to the second port 214 causes a pressure drop across the pilot feed orifice 230 and the longitudinal channel 229. As a result of the pressure drop, the pressure level of fluid in the chamber 238 becomes lower than the pressure level of fluid received at the first port 212. As a result, the fluid at the first port 212 applies a force on the annular surface areas 292 and 293 of the piston 224 in the proximal direction that is large than the force applied by fluid in the chamber 238 on the back end surface 294 of the piston 224 in the distal direction. Due to such force imbalance on the piston 224, the piston 224 moves or is displaced axially in the proximal direction and follows the pilot pin 226. As such, pressurized fluid at the first port 212 is relieved to the second port 214.

As shown in FIG. 10, the piston 224 and pilot pin 226 are displaced in the proximal direction. In the pressure relief mode, the pressure level at the first port 212 that causes the valve 200 to open is higher than the pressure level that opens the valve 200 in the pilot modulation mode. That is because in the pressure relief mode, no pilot pressure fluid signal is received at the pilot port 244 to assist the fluid received at the first port 212 in pushing the pilot pin 226 in the proximal direction. Also, as a result of the absence of a pilot pressure fluid signal, the distance that the piston 224 moves in the proximal direction in the pressure relief mode is smaller than the distance that it moves in the pilot modulation mode. This is evident by comparing, for example, an axial distance between the flanged portion 270 and the protrusion 268 in FIG. 10, to the distance between the flanged portion 270 and the protrusion 268 in FIG. 8.

Beneficially, the predetermined set pressure of the valve 200 operating in the pressure relief mode can be adjusted by sending a signal to the solenoid coil 254. As described above, providing an electric current to the solenoid coil 254 by an electronic controller of a hydraulic system results in the armature 256 applying a force to the solenoid spring 262 in the proximal direction via the solenoid sleeve 266, thereby reducing the preload force that the solenoid spring 262 applies to the pilot pin 226. Thus, the pressure setting can be adjusted by varying the electric current to the solenoid coil 254 to allow different pressure levels at the first port 212 to overcome the preload force of the solenoid spring 262 and open the valve 200.

The configurations and components shown in FIGS. 2-10 are examples for illustration, and different configurations and components could be used. For example, components can be integrated into a single component or a component can be divided into multiple components. As another example, different types of springs could be used, and other components could be replaced by components that perform a similar functionality.

FIG. 11 illustrates a hydraulic circuit 300 using the valve 200, in accordance with an example implementation. Similar components between the hydraulic circuit 300 and the hydraulic circuit 100 are designated with the same reference numbers. As shown in FIG. 11, the valve 200 replaces the counterbalance valve 122. The first port 212 of the valve 200 is fluidly coupled to the first chamber 116 and the second port 214 is fluidly coupled to the directional control valve 102. The pilot port 244 is fluidly coupled via the pilot line 126 to the hydraulic line 128 that fluidly couples the directional control valve 102 to the second chamber 118.

The hydraulic circuit 300 includes a controller 302 that could comprise any type of computing device configured to control operation of the hydraulic circuit 300 or a hydraulic system that includes the hydraulic circuit 300. The controller 302 may include one or more processors or microprocessors and may include data storage (e.g., memory, transitory computer-readable medium, non-transitory computer-readable medium, etc.). The data storage may have stored thereon instructions that, when executed by the one or more processors of the controller 302, cause the controller 302 to perform the operations described herein.

The hydraulic circuit 300 may include one or more pressure sensors such as pressure sensor 304 configured to measure pressure level in the first chamber 116 and pressure sensor 306 configured to measure pressure level in the second chamber 118. The pressure sensors 304, 306 are in communication with the controller 302 and provide to the controller 302 information indicative of the pressure levels respectively measured by the pressure sensors 304, 306. The controller 302 may then determine the load 114 based on the pressure levels in the chambers 116, 118 and the surface areas of the piston 108 in each chamber.

The hydraulic circuit 300 may additionally or alternatively include a load sensor configured to measure the load 114. Further, in some examples, the hydraulic circuit 300 may include one of the pressure sensors 304, 306, such as the pressure sensor 304 configured to measure the pressure level in the first chamber 116. Other types of sensors could be used to indicate the magnitude of the load 114.

In operation, to extend the piston 108, pressurized fluid is provided from the pump 120 through the directional control valve 102 and the reverse flow check 308 to the first chamber 116. The reverse flow check 308 is a symbolic representation of the reverse flow operation described above with respect to FIG. 5. Particularly, the piston 224 moves in the proximal direction under pressure (e.g., fluid having pressure level of 200 psi) allowing flow from the second port 214 through the annular flow area 282 and the cross holes 215A, 215B to the first port 212, which is coupled to the first chamber 116. As the piston 108 of the actuator 104 extends, fluid forced out of the second chamber 118 flows through the hydraulic line 128 and the directional control valve 102 to the tank 124.

To retract the piston 108 of the actuator 104, pressurized fluid is provided from the pump 120 through the directional control valve 102 and the hydraulic line 128 to the second chamber 118. As the piston 108 retracts, fluid in the first chamber 116 is forced out of the first chamber 116 through the hydraulic line 123 to the first port 212. Further, a pilot pressure fluid signal is received through the pilot line 126 at the pilot port 244.

The pilot pressure fluid signal received through the pilot line 126 at the pilot port 244 acts on the pilot pin 226 as described above with respect to FIGS. 6-9. The pilot pressure fluid signal, along with the fluid received at the first port 212 act against the solenoid spring 262 and the fluid in the groove 249. Once the combined action of the pilot pressure fluid signal and the fluid at the first port 212 overcome the pressure setting of the valve 200 and the force of the fluid in the groove 249, the valve 200 may open to allow fluid at the first port 212 to flow to the second port 214, then through the directional control valve 102 to the tank 124.

Additionally, the controller 302 may vary, adjust, or modify the pressure setting of the valve 200 by providing a signal to the solenoid actuator 206 (particularly, to the solenoid coil 254) of the valve 200. As described above, providing an electric signal to the solenoid coil 254 causes the armature 256 and the solenoid sleeve 266 coupled thereto to apply a force to the solenoid spring 262 in the proximal direction, thereby reducing the pressure setting of the valve 200.

In this manner, the controller 302 may monitor the load 114 through the information received from the pressure sensors 304, 306 or any other sensors to determine whether the load 114 is acting with gravity and inducing a large pressure in the first chamber 116 and the extent or value of the induced pressure in the first chamber 116. Accordingly, the controller 302 may send a signal to the solenoid coil 254 to vary the pressure setting of the valve 200.

In examples, the magnitude of the pressure setting may be inversely proportional to the magnitude of the electric signal provided to the solenoid coil 254. As such, if the load 114 is large and acting with gravity, then the controller 302 might not send a signal to the solenoid coil 254 or might send a signal with a small magnitude so as to maintain the pressure setting high and control lowering the load 114. On the other hand, if the load 114 is small or the actuator 104 is tilted at an angle such that gravitational force is reduced, the controller 302 may provide an electric signal with a larger magnitude to reduce the pressure setting of the valve 200. This way, the pressure level in the first chamber 116 that causes the valve 200 to open may be reduced. As a result, the hydraulic circuit 300 operates more efficiently and energy loss is reduced.

The hydraulic circuit 300 is an example circuit in which the valve 200 could be used; however, the valve 200 could be used in other hydraulic circuits and systems as well. For instance, rather than using a four-way direction control valve that controls flow to both chambers 116, 118, a separate two or three way valve could be used to independently meter fluid into each of the chambers 116, 118. In this case, two valves 200 could be used, one valve 200 for each chamber to control flow forced out of each chamber.

Further, in some examples, rather than having fluid exiting the valve 200 at the second port 214 flowing through the directional control valve 102 before being delivered to the tank 124, the valve 200 can be configured as a meter-out element while a two- or three-way directional control valve is configured as a meter-in element. In this configuration, the second port 214 could be fluidly coupled to the tank 124 such that fluid exiting the valve 200 flows to the tank 124 without flowing through a directional control valve.

In some examples, the directional control valves could be electrically operated as well, and in these examples, the controller 302 may be configured to send signals to the directional control valves to actuate them based on the sensor information received from the pressure sensors 304, 306. Other configurations are possible.

FIG. 12 is a flowchart of a method 400 for controlling a hydraulic circuit, in accordance with an example implementation. The method 400 could, for example, be performed by a controller such as the controller 302.

The method 400 may include one or more operations, or actions as illustrated by one or more of blocks 402-404. Although the blocks are illustrated in a sequential order, these blocks may in some instances be performed in parallel, and/or in a different order than those described herein. Also, the various blocks may be combined into fewer blocks, divided into additional blocks, and/or removed based upon the desired implementation.

In addition, for the method 400 and other processes and operations disclosed herein, the flowchart shows operation of one possible implementation of present examples. In this regard, each block may represent a module, a segment, or a portion of program code, which includes one or more instructions executable by a processor or a controller for implementing specific logical operations or steps in the process. The program code may be stored on any type of computer readable medium or memory, for example, such as a storage device including a disk or hard drive. The computer readable medium may include a non-transitory computer readable medium or memory, for example, such as computer-readable media that stores data for short periods of time like register memory, processor cache and Random Access Memory (RAM). The computer readable medium may also include non-transitory media or memory, such as secondary or persistent long term storage, like read only memory (ROM), optical or magnetic disks, compact-disc read only memory (CD-ROM), for example. The computer readable media may also be any other volatile or non-volatile storage systems. The computer readable medium may be considered a computer readable storage medium, a tangible storage device, or other article of manufacture, for example. In addition, for the method 400 and other processes and operations disclosed herein, one or more blocks in FIG. 10 may represent circuitry or digital logic that is arranged to perform the specific logical operations in the process.

At block 402, the method 400 includes receiving sensor information indicative of a load on an actuator in a hydraulic circuit. As mentioned above, a hydraulic circuit such as the hydraulic circuit 300 could include one or more pressure sensors 304, 306 coupled to respective chambers of a hydraulic actuator. The controller 302 may receive information from the pressure sensors 304, 306 and may accordingly determine a magnitude the load 114 that the actuator 104 is subjected to. Additionally or alternatively, the hydraulic circuit may include a load cell that may provide to the controller 302 information indicative of the magnitude of the load 114. Other parameters or variables can be used to indicate the magnitude of the load 114. For instance, variation in pressure level of the pilot pressure fluid signal could be used. Also, parameters of a machine including parameters associated with the actuator 104 could be used, such as position or speed of the piston 108 indicated by a position or velocity sensor. As another example for illustration, if the actuator 104 drives a drill of a vertical drilling machine, for instance, a length of the drill could be used to indicate a weight that the drill is subjected to. As another example, wind speed could be used to indicate a particular type of load on an actuator. Other example parameters could be used based on the type of application.

At block 404, the method 400 includes, based on the sensor information, sending a signal to the solenoid actuator 206 of the valve 200 to adjust the pressure setting of the valve 200. As described above, the controller 302 may provide a signal to the solenoid coil 254 to cause the armature 256 to apply a force on the solenoid spring 262 and accordingly adjust the pressure setting of the valve 200.

For example, in an overrunning load case where the piston 108 of the actuator 104 retracts the load 114 that is a large negative load acting with gravity assistance, a large induced pressure in the first chamber 116 and a low pressure in the second chamber 118 result. Accordingly, the controller 302 might not send a signal to the solenoid coil 254 or may send a signal with a small magnitude so as to have a high pressure setting for the valve 200 and lower the load 114 controllably. As the hydraulic circuit operates and the actuator 104 moves, the load 114 may change (e.g., the angle of the actuator 104 relative to the ground surface may change). For instance, the load 114 may be begin to decrease or change to a positive load where pressurized fluid in communicated to the second chamber 118 to cause the piston 108 to retract and pull the load 114. In this case, pressure level in the first chamber 116 may be reduced and the pilot pressure fluid signal may have a high pressure level. Accordingly, the controller 302 may send a signal to the solenoid coil 254 to decrease the pressure setting of the valve 200. As such, the controller 302 may continually adjust the pressure setting of the valve 200 during operation of the hydraulic circuit 300 based on the sensor information.

FIG. 13 is a flowchart of a method 500 for operating a valve, in accordance with an example implementation. The method 500 shown in FIG. 13 presents an example of a method that could be used with the valve 200 shown throughout the Figures, for example. The method 500 may include one or more operations, functions, or actions as illustrated by one or more of blocks 502-510. Although the blocks are illustrated in a sequential order, these blocks may also be performed in parallel, and/or in a different order than those described herein. Also, the various blocks may be combined into fewer blocks, divided into additional blocks, and/or removed based upon the desired implementation. It should be understood that for this and other processes and methods disclosed herein, flowcharts show functionality and operation of one possible implementation of present examples. Alternative implementations are included within the scope of the examples of the present disclosure in which functions may be executed out of order from that shown or discussed, including substantially concurrent or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art.

At block 502, the method 500 includes receiving the pilot pressure fluid signal at the pilot port 244 of the valve 200.

At block 504, the method 500 includes applying via the pilot pressure fluid signal a pressure on the pilot pin 226. The pilot pressure fluid signal is communicated through the cross hole 246 and slanted channel 248 to the annular space 250 and the second annular groove 288 of the pilot pin 226, and the pilot pressure fluid signal then applies a pressure on the pilot pin 226 in the proximal direction.

At block 506, the method 500 includes causing the pilot pin 226 to move axially in an opening (proximal) direction. As the pilot pressure fluid signal acts on the areas A₄and A₃shown in FIG. 6, a force acts on the pilot pin 226 in the proximal or opening direction against the force applied to the pilot pin 226 via the solenoid spring 262. When the force that the pilot pressure fluid signal applies to the pilot pin 226 along with the force applied on the pilot pin 226 via the pressurized fluid received at the first port 212 and communicated to the first annular groove 286 reaches a particular force level that overcomes the biasing force of the solenoid spring 262 and the force applied by the fluid in the groove 249 on the areas A₆and A₅, the pilot pin 226 moves in the opening direction.

At block 508, the method 500 includes receiving an electric signal energizing the solenoid coil 254 of the solenoid actuator 206 of the valve 200. A controller of the hydraulic system or hydraulic circuit (e.g., the hydraulic circuit 300) may receive information indicating a particular pressure level at a chamber of an actuator or indicating a magnitude of the load that the actuator is subjected to, and accordingly the controller may provide a command or electric signal to the solenoid coil 254 to adjust the pressure setting of the valve 200. As mentioned above, many other variables could be used to indicate the magnitude of the load that the actuator is subject to based on the application in which the actuator is used. Thus, any other type of sensor could be used to provide information to the controller that indicates the magnitude of the load or a change in magnitude of the load.

At block 510, the method 500 includes, in response to receiving the electric signal, causing the armature 256 to apply a force on the solenoid spring 262, thereby reducing the biasing force that the solenoid spring 262 applies to the pilot pin 226. Reducing the biasing force that the solenoid spring 262 applies to the pilot pin 226 reduces the pressure setting of the valve 200.

The detailed description above describes various features and operations of the disclosed systems with reference to the accompanying figures. The illustrative implementations described herein are not meant to be limiting. Certain aspects of the disclosed systems can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.

Further, unless context suggests otherwise, the features illustrated in each of the figures may be used in combination with one another. Thus, the figures should be generally viewed as component aspects of one or more overall implementations, with the understanding that not all illustrated features are necessary for each implementation.

Additionally, any enumeration of elements, blocks, or steps in this specification or the claims is for purposes of clarity. Thus, such enumeration should not be interpreted to require or imply that these elements, blocks, or steps adhere to a particular arrangement or are carried out in a particular order.

Further, devices or systems may be used or configured to perform functions presented in the figures. In some instances, components of the devices and/or systems may be configured to perform the functions such that the components are actually configured and structured (with hardware and/or software) to enable such performance. In other examples, components of the devices and/or systems may be arranged to be adapted to, capable of, or suited for performing the functions, such as when operated in a specific manner.

By the term “substantially” or “about” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide

The arrangements described herein are for purposes of example only. As such, those skilled in the art will appreciate that other arrangements and other elements (e.g., machines, interfaces, operations, orders, and groupings of operations, etc.) can be used instead, and some elements may be omitted altogether according to the desired results. Further, many of the elements that are described are functional entities that may be implemented as discrete or distributed components or in conjunction with other components, in any suitable combination and location.

While various aspects and implementations have been disclosed herein, other aspects and implementations will be apparent to those skilled in the art. The various aspects and implementations disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims, along with the full scope of equivalents to which such claims are entitled. Also, the terminology used herein is for the purpose of describing particular implementations only, and is not intended to be limiting.

	Number	Date	Country
Parent	15954884	Apr 2018	US
Child	16662364		US

Electrohydraulic Counterbalance and Pressure Relief Valve

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