Research Of Intrinsically Safe High Flow Solenoid Bally Valve

In the hydraulic control system of a hydraulic support, the oil circuit switching is normally controlled by a main valve driven by the pilot valve. With the increasing demanded speed of the hydraulic support, the flow rate of main valve and pilot valve is increasing. But the maximum flow rate of existing solenoid pilot valves,1.6L/min, is small, the research and design of solenoid pilot valve with high flow have become increasingly important. In addition, a combination of a solenoid pilot valve and main valve in small flow hydraulic control system can be replaced by the high flow solenoid pilot valve, which has simplified the system and improved the work efficiency.By analyzing the structural forms of common solenoid pilot valve, this paper designed a high flow solenoid pilot valve, also called electromagnetic ball valve, constituted by a solenoid electromagnet and a ceramic ball valve core with small operating force. The mathematical model of electromagnetic ball valve is achieved by performing stress analysis and calculation of the various components. After parameterized solving the mathematical mode numerically based on MATLAB software, the initial values of the relevant parameters are determined and the dynamic performance of the electromagnetic ball valve is researched.Then the coupled electro-hydraulic system is set up based on AMESim software, where the cylinder with load is controlled by the high flow electromagnetic ball valve directly, and the characteristics are analyzed, such as the spool displacement, outlet pressure, outlet flow and flow-pressure characteristics. The results show that the designed high flow electromagnetic ball valve has fast response that the valve achieved stable just takes0.006s, small overshoot which is0.2mm, excellent dynamic performance and flow-pressure characteristics, and the outlet flow reaches8.3L/min under1.9MPa of differential pressure, which are complained with the design requirements completely. In addition, some key parameters, such as the spool stroke, the seat cone angle, the gap of the damping pin and the diameter of the fixed orifice, have a great effect on characteristics of the electromagnetic ball valve, and the parameter values should be choose reasonably.Finally, under numerical analyzing of the internal flow field of the designed solenoid ball valve based on FLUENT software, the performances of the flow field are achieved, such as the filled pressure distribution, the filled velocity distribution, the filled turbulent kinetic energy distribution and the velocity vector distribution, and the performances of the flow field at different structural dimensions are discussed, which are beneficial to optimizing the flow channel structure. The results show that the gradient of the pressure drop at the valve opening is biggest, where the flow speed is fastest and up to18.7m/s, and the turbulent kinetic energy is large and up to1080kgm2/s2. Because of the designed flow channel structure of the solenoid ball valve is relatively reasonable, there is no clear negative pressure area and whirlpool area, the inlet and outlet pressure ire evenly distributed, and fluid flow are standard laminar flow. In addition, the opening of the seat, the seat cone angle and the differential pressure have a great effect on the flow field performance. The flow field has a better comprehensive performance when the opening range from0.4mm to0.5mm, the seat cone angle range from30°to35°and the differential pressure is within the rated range.This paper has achieved a series of effective methods on parametric analysis of mathematical model, structural design and structural optimization of electromagnetic ball valve with large flow, which make a reference for further research on the electromagnetic ball valve with large flow.