Sliding spool design for reducing the actuation forces in direct operated proportional directional valves: Experimental validation

• An innovative procedure to design a commercial proportional directional valve is shown.
• Experimental tests are performed to demonstrate the flow force reduction.
• The design is improved by means of a previously made optimization procedure.
• Great reduction in the flow forces without reducing the flow rate is demonstrated.

This paper presents the experimental validation of a new methodology for the design of the spool surfaces of four way three position direct operated proportional directional valves. The proposed methodology is based on the re-design of both the compensation profile (the central conical surface of the spool) and the lateral surfaces of the spool, in order to reduce the flow forces acting on the spool and hence the actuation forces. The aim of this work is to extend the application range of these valves to higher values of pressure and flow rate, thus avoiding the employment of more expensive two stage configurations in the case of high-pressure conditions and/or flow rate. The paper first presents a theoretical approach and a general strategy for the sliding spool design to be applied to any four way three position direct operated proportional directional valve. Then, the proposed approach is experimentally validated on a commercially available valve using a hydraulic circuit capable of measuring the flow rate as well as the actuation force over the entire spool stroke. The experimental results, performed using both the electronic driver provided by the manufacturer and a manual actuation system, show that the novel spool surface requires remarkably lower actuation forces compared to the commercial configuration, while maintaining the same flow rate trend as a function of the spool position.