1

Desi gn, anal ysi s and manuf act uri ng of Current t o Pressure Convert er f or
St eam Turbi ne
A PROJECT REPORT
SUBMITTED BY
Darshik Sheth (100410119031)
Meet Patel (100410119010)
Shravan Ranade (100410119018)
Vaishal Shah (100410119035)
In partial fulfillment for the award of the degree
Of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING DEPARTMENT
Of
SARDAR VALLABHBHAI PATEL INSTITUTE OF TECHNOLOGY,
VASAD
GUJARAT TECHNOLOGICAL UNIVERSITY,
DECEMBER, 2013
2
ACKNOWLEDGEMENTS
This project would not have been complete without the support of many people. We
would like to give a special thanks to Mrs. Hetal Chauhan for her assistance and
guidance throughout this project work. We would also like to thank Mr. Hitesh Vakil,
Mr. Pankaj Shah and Mr. Vipul Shah from SIEMENS Ltd. for their expert guidance,
comments and suggestions. Without the help of their knowledge and expertise in every
facet of the study, from helping to find the relevant formulas and to analyzing the results,
this project could not have been completed. We would finally like to give special thanks
to all our family and friends who have given us support throughout the past 6 months,
because without them none of this would have been possible.
3
ABSTRACT
As we know, the world today is unimaginable without electricity. Large scale electrical
energy production largely depends on the use of turbines. Nearly all of the world's power
that is supplied to a major grid is produced by turbines. A turbine is a simple device with
few parts that uses flowing fluids (liquids or gases) to produce electrical energy. Fluid is
forced across blades mounted on a shaft, which causes the shaft to turn. The energy
produced from the shaft rotation is collected by a generator which converts the motion to
electrical energy using a magnetic field.
The controlling of the turbines was done initially by mechanical governors. Now, with the
technological advancement, they are replaced by the electronic governors.
Steam turbine governing is the procedure of controlling the flow rate of steam into a
steam turbine so as to maintain its speed of rotation as constant
This project is dedicated to the study and design of a Current to Pressure Converter,
which converts the electric signal from the governor to the hydraulic signal, which further
controls the servomechanism.
It forms an integral part of the controlling. CPC quickly and accurately converts the input
signal into a proportional output pressure. This is important as the turbine should function
as expected in load variant conditions and also stop in abnormal conditions.
4
SARDAR VALLABHBHAI PATEL INSTITUTE OF TECHNOLOGY, VASAD
MECHANICAL ENGINEERING DEPARTMENT
CERTIFICATE
This is to certify that the dissertation entitled Desi gn, anal ysi s and manufact uri ng of
Current to Pressure Convert er for St eam Turbi ne has been carried out by Darshik
Sheth, Meet Patel, Shravan Ranade, Vaishal Shah under my guidance in partial
fulfillment of the degree of Bachelor of Engineering in Mechanical Engineering (VII
th
Semester) of Gujarat Technological University during the Academic Year 2013 14.
Internal Guide: External Guide:
Prof. Hetal R. Chauhan, Mr. Pankaj F. Shah
Assistant Professor, Designing Head, Core Engineering,
Mechanical Engineering Department Siemens Ltd.
External Examiner: Dr. P. V. Ramana
Head, Mechanical Engg. Department
5
INDEX
Chapter 1: Introduction
1.1 Company Background ...12
1.2 Company Product ...13
1.3 Objective of project 13
1.4 Topic Overview...13
1.5 Project Methodology..14
Chapter 2: CPC in Brief
2.1 Why Fuel Control Is Required in Turbines? ..16
2.2 Steam Control System in Turbines .....17
2.3 Working of CPC .....19
Chapter 3: Literature Study
3.1 Orifice .....................................................................23
3.1.1 Flow coefficient..........................................................................24
3.2 Spool ...25
3.3 Seals ...26
3.4 O-ring ..28
3.4.1 Advantages of O-ring29
3.4.2 O-ring Operations...30
3.5 Solenoid Operated Flow Valve (USRE326644E)...32
6
3.6 Solenoid Valve (US5469886A)..35
3.7Direct Solenoid operated directional control valve (US4338966A)..38
Chapter 4: Design Phase
4.1 Introduction ....44
4.2 Design of Orifice.....45
4.3 Bore Diameter.46
4.4 Oil Seal Selection47
Chapter 5: Conclusion and Future plans
5.1 Conclusion...54
5.2 Future Plans.54
References.56
7
LIST OF TABLES
Table No. Table Description Page No.
2.1 Comparison of Throttle & Nozzle control 19
4.1 Temperature Range for common elastomers 49
4.2 Comparison of commonly used elastomers 50
8
LIST OF SYMBOLS
SYMBOL ABBREVIATIONS
I Current
SG Specific Gravity
Q Flow rate
Cv Flow coefficient
N Turbine Rpm
P Pressure
o
C Degree Centigrade
o
F Degree Fahrenheit
F Frequency
p Pole
D Diameter
L Length
mA Milli-Ampere
E,V Voltage
R Resistance
r Radius
A C/S area
9
LIST OF FIGURES
Figure No. Figure Description Page No.
2.1 Steam Turbine Speed Control System 18
2.2 Nozzle governing 19
2.3 Working principle of CPC 20
2.4 Logic of CPC 21
3.1 Pressure difference v/s Voltage analogy 23
3.2 Spool (Source: Parker O-Ring Manual) 25
3.3 Static seals (Source: Parker O-Ring Manual) 26
3.4 Dynamic seals (Source: Parker O-Ring Manual) 27
3.5 Rotary seals (Source: Parker O-Ring Manual) 27
3.6 Seat seals (Source: Parker O-Ring Manual) 28
3.7 O-ring (Source: Parker O-Ring Manual) 29
3.8 O-ring Operation (Source: Parker O-Ring Manual) 31
3.9
O-ring under pressure (Source: Parker O-Ring
Manual)
31
3.10 O-ring Extruding (Source: Parker O-Ring Manual) 31
3.11 O-ring Failure (Source: Parker O-Ring Manual) 31
10
3.12
Side view partly in cross section of a remotely
controlled hydraulic flow valve, illustrating a
preferred embodiment of the invention
(Source: USRE32466)
32
3.13
Cross-sectional view of a solenoid valve according
to a preferred embodiment of the invention
(Source: US 5469886 A)
35
3.14
FIG. 1 is a cross sectional view of one embodiment
of the valve of the present invention in which
pressure fluid from a source is normally applied to a
fluid responsive element;
FIG. 2 is a cross sectional view of another
embodiment of the valve of the present invention in
which pressure fluid from a source is normally
vented to a return line or reservoir;
FIG. 3 is a right end view of the valve of the present
invention, certain parts being eliminated for clarity;
and
FIG. 4 is a cross sectional view taken through the
guide portion of the plunger of the FIG. 1
embodiment along line 4--4.
(Source: US4338966)
38
4.1 Introduction of CPC 44
4.2
Spirax Sarco Calculator (Source: Spirax Sarco
website)
45
4.3
Compressibility Chart (Source: Parker O-Ring
Manual)
50
4.4
2-0XX sizes Chart for O-Ring Selection (source:
Parker O-Ring Manual)
52
11
CHAPTER 1
Introduction
12
1.1 Company Background
R. S. No. 144-A,
Opp. Makarpura Railway Station,
Maneja, Vadodara
Industry Coordinator : Mr. Pankaj Shah
The Siemens Group in India has emerged as a leading inventor, innovator and
implementer of leading-edge technology enabled solutions operating in the core business
segments of Industry, Energy, Healthcare and Infrastructure and Cities. The Groups
business is represented by various companies that span across these various segments.
Siemens brings to India state-of-the-art technology that adds value to customers through a
combination of multiple high-end technologies for complete solutions. The Group has the
competence and capability to integrate all products, systems and services. It caters to
Industry needs across market segments by undertaking complete projects such as
Hospitals, Airports and Industrial units.
The Siemens Group in India comprises of 17 companies, providing direct employment to
over 18,000 persons. Currently, the group has 21 manufacturing plants, a wide network of
Sales and Service offices across the country as well as over 500 channel partners.
Today, Siemens, with its world-class solutions plays a key role in Indias quest for
developing modern infrastructure.
Siemens unit at Maneja, Vadodara comes under Energy Sector (Oil and gas Division) and
has main products including Steam Turbine systems.
13
1.2 Company Products
Industry
Industrial Automation
Drive Technology
Burning Technology
Osram
Industrial Solution
Mobility
Energy
Oil & Gas
Fossil Power Generation
Renewable Energy Division
Power Transmission
Power Distribution
Healthcare
Workflow & Solution
Diagnosis
1.3 Objective of Project
To facilitate the localization of the product and make the product in-house
1.4 Topic Overview
This Project Report is based on developing the current to pressure converter, which is
basically a solenoid valve. It is an important component in the controlling of the steam in
case of the turbines.
The aim of this project is to develop this product to facilitate the in-house production of
this product.
14
1.5 Project Methodology
Understanding the basic concept
Literature study
Recognition of new system
Design of new mechanism
Preparation of model
Conducting of tests
Comparison with existing systems
15
CHAPTER 2
Brief Introduction to need of CPC
16
2.1 Why Fuel control is required in turbines?
For getting electricity at constant frequency turbine should rotate at constant speed & the
relation between frequency & RPM in generator is given by:
N= (120f/P)
Where
N = Rpm of turbine
f = Frequency
P = poles
so for F= 50Hz, P=4, N=1500 RPM
So at different Electrical load, if speed will remain same then we will get constant
frequency.
Initially when steam/gas turbines were developed, mechanical governors were used. But
due to less efficiency, wear and friction problems now it is replaced by electronic
governors.
17
2.2 Speed Control System in Steam Turbine
Steam turbine governing is the procedure of controlling the flow rate of steam into
a steam turbine so as to maintain its speed of rotation as constant. The variation in load
during the operation of a steam turbine can have a significant impact on its performance.
In a practical situation the load frequently varies from the designed or economic load and
thus there always exists a considerable deviation from the desired performance of the
turbine. The primary objective in the steam turbine operation is to maintain a constant
speed of rotation irrespective of the varying load. This can be achieved by means
of governing in a steam turbine.
Principal types of Steam turbine governing are:
Throttle Governing
Nozzle Governing
Bypass Governing
Combination Governing
Emergency Governing
In nozzle governing the flow rate of steam is regulated by opening and shutting of sets of
nozzles rather than regulating its pressure. In this method groups of two, three or more
nozzles form a set and each set is controlled by a separate valve. The actuation of
individual valve closes the corresponding set of nozzle thereby controlling the flow rate.
These individual valves are controlled by servo mechanism, actuated by the CPC, based
on the governor signal.
18
Fig 2.1 Steam Turbine Speed Control System
DETAILS ON NOZZLE GOVERNING (Mechanism and working)
The efficiency of steam turbines is considerably reduced if throttle governing is carried
out at low loads. An alternative and more efficient of governing is by means of nozzle
control.
Figure shows a diagrammatic arrangement of nozzle governing system in which 3 to 5 or
more nozzles are worked together and supply steam to turbines. At full load nozzles are
fully opened and at less loads nozzle openings are controlled by valve chest which is
controlled by servo mechanism.
19

Fig 2.2 Nozzle Governing
Table 2.1 Comparison of Throttle & Nozzle control
Sr No. Aspects Throttle control Nozzle control
1 Throttling losses Severe No throttling losses
2 Partial admission losses Low High
3 Heat drop available Lesser Larger
4 Suitability Small turbines Medium and larger turbines

20
2.3 Working of CPC
A set signal of 4-20 mA is generated by the electronic governor. This signal is based on
the load on the turbine/governor. The signal generates a magnetic force in the solenoid,
the limits of which can be adjusted by means of the potentiometers and which is then
transmitted onto the control piston via tappet.
The hydraulic force is generated due to the pressure of incoming hydraulic oil at 9 bar (g)
pressure. The hydraulic force being proportional to the output signal pressure acts against
this force.
In the case of the two forces being equal, the control piston is positioned in the hydraulic
center. In this situation, the output signal pressure corresponds to the set signal. In the
hydraulic center position the control piston performs minimum oscillating movements
in the area of the guiding edges PP
A
and P
A
T, in order to keep the output pressure P
A
on the value set by magnetic force.
Fig 2.3
21
Fig. 2.4 Logic of CPC
When increasing the set signal and thus magnetic force from this condition, the control
piston position changes and thus connects the output pressure P
A
to the feed pressure P
and blocks P
A
towards the tank return line. Now pressure P
A
will increase until the same
has returned the control piston to the "hydraulic center" and P
A
corresponds to the new set
signal. The spring force of the control spring generates a force-offset in order to guarantee
the I/H converter function for output pressures of approx. 0 bar, too. The internal leakage
is fed back into tank return line.
22
Chapter 3
Literature Review
4.1 Orifice
Fundamentals
Pressure difference and voltage difference analogy
So,
I (Current) Q (Flow) &
V (Voltage) P (Pressure)
In electrical circuit we used to find resistance.
But in Hydraulic circuit finding out resistance is difficult so we find conductance which is
the reciprocal of the resistance. Denoted by C Or K

Pressure = Flow*Resistance
Pressure = Flow*(1/Conductance
Pressure difference and voltage difference analogy
Fig 4.1
Q (Flow) &
P (Pressure)
circuit we used to find resistance.
But in Hydraulic circuit finding out resistance is difficult so we find conductance which is
the reciprocal of the resistance. Denoted by C Or K
Pressure = Flow*Resistance
Pressure = Flow*(1/Conductance
23
But in Hydraulic circuit finding out resistance is difficult so we find conductance which is
24
And this C value is known as Flow coefficient.
4.1 Flow coefficient
The flow coefficient of a device is a relative measure of its efficiency at
allowing fluid flow.
It describes the relationship between the pressure drop across an orifice, valve or other
assembly and the corresponding flow rate.
Mathematically the flow coefficient can be expressed as:
C
V
=
??
?

where:
Cv = Flow coefficient or flow capacity rating of valve.
F = Q=Rate of flow (US gallons per minute).
SG = Specific gravity of fluid (Water = 1).
P = Pressure drop across valve (psi).
In more practical terms, the flow coefficient Cv is the volume (in US gallons) of water at
60F that will flow per minute through a valve with a pressure drop of 1 psi across the
valve.
25
The use of the flow coefficient offers a standard method of comparing valve capacities
and sizing valves for specific applications that is widely accepted by industry.
In our project after finding out Cv value we are able to find out minimum orifice size
that is required to meet the specifications.
4.2 Spool
Spool is of two types namely sliding and rotary. Sliding spool is cylindrical in cross
section, and the lands and grooves are also cylindrical. Rotary valves have sphere-like
lands and grooves in the form of holes drilled through the spheres.
The type of spool used in our project is of sliding type.
Fig 3.2 Spool
26
4.3 Seals
Types of Seals
1. Static Seals
2. Dynamic Seals
3. Rotary Seals
4. Seat Seals
1.Static Seals
They are used when no relative movement occurs between the mating parts.The seal is
usually compressed between two adjacent parts securing the two stationary parts together
by fasteners.
Example : Static seal may be used between the pump housing and the end plate.
Fig 3.3 Static Seals
27
2.Dynamic Seals
They are used between the surfaces of hydraulic parts where movement occurs and
controls both leakage and lubrication. In certain dynamic seals wipers or covering boots
are used to keep away dirt and foreign materials.
Example : Use of road wiper.
Fig 3.4 Dynamic seals
3.Rotary Seals
In a rotary seal, either the inner or outer member of the sealing elements turn (around the
shaft axis) in one direction only. This applies when rotation is reversible, but does not
allow for starting and stopping after brief arcs of motion, which is classed as an
oscillating seal. Examples of a rotary seal include sealing a motor or engine shaft, or a
wheel on a fixed axle. See Figure 4.5.
Fig 3.5 Rotary Seals
28
4. Seat Seals
In a seat seal, the O-ring serves to close a flow passage as one of the contact members.
The motion of closing the passage distorts the O-ring mechanically to create the seal, in
contrast to conditions of sealing in previously dened types. A sub-classication is
closure with impact as compared with non-impact closure. Examples of a seat-seal
include O-ring as a washer on the face of a spiral threaded valve, a seal on the cone of a
oating check valve, and a seal on the end of a solenoid plunger. See Figure 4.6
Fig 3.6 Seat Seals
We have selected O-ring type of seal according to shape.
4.4 O-ring
What is an O-Ring?
An O-ring is a torus, or doughnut-shaped ring, generally molded from an elastomer,
although O-rings are also made from PTFE and other thermoplastic materials, as well as
metals, both hollow and solid.
O-rings are used primarily for sealing. O-rings are also used as light-duty, mechanical
drive belts.
29
What is an O-Ring Seal?
An O-ring seal is used to prevent the loss of a uid or gas. The seal assembly consists of
an elastomer O-ring and a gland. An O-ring is a circular cross-section ring molded from
rubber . The gland usually cut into metal or another rigid material contains and supports
the O-ring . The combination of these two elements; O-ring and gland constitute the
classic O-ring seal assembly.
Fig 3.7 O-Ring
4.4.1 Advantages of O-Rings
They seal over a wide range of pressure, temperature and tolerance.
Ease of service, no smearing or retightening.
No critical torque on tightening, therefore unlikely to cause structural damage.
O-rings normally require very little room and are light in weight.
In many cases an O-ring can be reused, an advantage over non-elastic at seals and
crush-type gaskets.
The duration of life in the correct application corresponds to the normal aging period of
the O-ring material.
30
O-ring failure is normally gradual and easily identi ed.
Where differing amounts of compression effect the seal function (as with at gaskets), an
O-ring is not effected because metal to metal contact is generally allowed for.
They are cost-effective.
4.4.2 O-ring Operation
Operation All robust seals are characterized by the absence of any pathway by which
uid or gas might escape. Detail differences exist in the manner by which zero clearance is
obtained welding, brazing, soldering, ground ts or lapped nishes or the yielding of a
softer material wholly or partially con ned between two harder and stiffer members of
the assembly. The O-ring seal falls in the latter class.
The rubber seal should be considered as essentially an incompressible, viscous uid
having a very high surface tension. Whether by mechanical pressure from the surrounding
structure or by pressure transmitted through hydraulic uid, this extremely viscous uid is
forced to ow within the gland to produce zero clearance or block to the ow of the
less viscous uid being sealed. The rubber absorbs the stack-up of tolerances of the unit
and its internal memory maintains the sealed condition. Figure 4.8 illustrates the O-ring
as installed, before the application of pressure. Note that the O-ring is mechanically
squeezed out of round between the outer and inner members to close the uid passage.
The seal material under mechanical pressure extrudes into the microne grooves of the
gland. Figure 4.9 illustrates the application of uid pressure on the O-ring. Note that the
O-ring has been forced to ow up to, but not into, the narrow gap between the mating
surfaces and in so doing, has gained greater area and force of sealing contact. Figure 4.10
shows the O-ring at its pressure limit with a small portion of the seal material entering the
narrow gap between inner and outer members of the gland. Figure 4.11 illustrates the
result of further increasing pressure and the resulting extrusion failure. The surface
tension of the elastomer is no longer sufcient to resist ow and the material extrudes
(ows) into the open passage or clearance gap.
31
Fig 3.8 O-ring installed
Fig 3.9 O-ring under pressure
Fig 3.10 O-ring Extruding
Fig 3.11 O-ring failure
4.5 Solenoid controlled flow valve
A pilot operated flow regulating valve which can be remotely controlled by varying the
energization to a solenoid. The valve consists of a normally
pressure-differential-actuated, main valve element and a pressure
valve employing a solenoid acting like a remotely controllable electromagnetic spring to
control the flow of fluid through the pilot valve and the pressure difference across the
main valve element.
Figures 3
Description
The present invention provides a flow valve which overcomes the problems of the prior
art, provides a flow valve which may be easily regulated by the amount of electric current
supplied to a solenoid coil.
Solenoid controlled flow valve (US RE32644 E)
A pilot operated flow regulating valve which can be remotely controlled by varying the
to a solenoid. The valve consists of a normally-closed, spring
actuated, main valve element and a pressure-compensated, pilot flow
valve employing a solenoid acting like a remotely controllable electromagnetic spring to
ol the flow of fluid through the pilot valve and the pressure difference across the
3.12 Solenoid controlled flow valve
The present invention provides a flow valve which overcomes the problems of the prior
provides a flow valve which may be easily regulated by the amount of electric current
32
A pilot operated flow regulating valve which can be remotely controlled by varying the
closed, spring-biased,
compensated, pilot flow
valve employing a solenoid acting like a remotely controllable electromagnetic spring to
ol the flow of fluid through the pilot valve and the pressure difference across the
The present invention provides a flow valve which overcomes the problems of the prior
provides a flow valve which may be easily regulated by the amount of electric current
33
In accordance with the invention, a remotely controllable fluid flow valve is provided,
comprised of a three-ported, main valve section including a mechanical spring biased,
pressure-differential-actuated, main valve element and a two ported, pressure-
compensated, pilot-type flow valve including a solenoid acting as a variable
electromagnetic spring to variably control the volume of fluid flowing through the pilot
valve and the pressure difference across the main valve element.
More specifically in accordance with the invention, a flow valve is provided comprised of
a housing having an elongated cylindrical cavity with a pressure inlet and a first outlet
port, a first valve element operable to control the flow of fluid between the ports and
having a first surface exposed to inlet pressure and a second oppositely facing surface
exposed to pressures in a variable pressure chamber, mechanical spring means lightly
biasing the element to an initial position relative to the ports, fixed orifice means
communicating the inlet port with the chamber, a second outlet port communicating the
chamber to low pressure, a second valve element operable to control the flow of fluid
through the second port and an electro-magnetic spring for controlling the position of this
second valve element relative to the second port comprised of a solenoid including a
solenoid coil, a sleeve-like, armature-attracting pole piece and an axially spaced, sleeve-
like, armature-supporting pole piece with the armature so positioned relative to the pole
pieces that as the armature moves into the attracting pole piece, the magnetic force
decreases. To provide this, the armature must substantially overlap the supporting pole
piece and slightly overlap the attracting pole piece.
Further in accordance with the invention, the valve is comprised of: a housing having an
elongated cylindrical cavity with an inlet port and a main outlet port; a valve element in
the form of a piston slidable in the cavity to restrict the outlet port and having one end
surface exposed to the inlet pressure and an opposite surface defining with the cavity a
variable pressure chamber; mechanical spring means biasing the element to the valve
closed position; a fixed orifice through the piston communicating inlet pressure with the
variable pressure chamber; an outlet port communicating the variable pressure chamber to
low pressure and a pilot valve element movable to restrict this latter port; a magnetically
permeable armature operatively associated with the pilot valve element; a solenoid coil
and magnetic field poles arranged to exert an axial force on the armature; the armature
and the field pole being so arranged that as the armature moves further into one of the
field poles, the magnetic force decreases; and, an axially facing orifice operatively
associated with the pilot valve element for exerting a flow force thereon and provide
pressure compensated flow through the pilot valve.
In essence, when the solenoid is energized to a given level, the valve element is moved to
effect communication of the chamber with the pilot valve outlet port and permit flow of
fluid through the main valve orifice and the pilot valve orifice in a volume which is
pressure compensated, that is, it is constant above a certain minimum pressure regardless
34
of inlet system pressure above that minimum pressure. This pilot flow creates a pressure
differential across the main valve element which then is moved to the open position by
the pressure differential across the valve element creating a pressure force in opposition
to the mechanical spring bias. This permits flow of fluid from the inlet port through the
main outlet port in an amount proportional to the pressure differential which will remain
constant for all values of inlet pressure above a minimum.
Summary
This invention pertains to the art of fluid valves, and more particularly to an electrically
controlled flow valve.
The invention is particularly applicable to hydraulic flow valves operating at pressures up
to 6,000 pounds per square inch and will be described with particular reference thereto,
although it will be appreciated that the invention has broader applications and may be
used in many types of valves either for controlling the flow of liquids or gases.
Flow valves are used extensively in industry to control the volume of fluid flowing from a
fixed volume hydraulic pump to a motor or other apparatus, the speed of which must be
controlled.
Such valves in the past have usually included an adjustable variable orifice, the opening
of which is controlled by a threaded element which may be manually adjusted or driven
by a remotely controlled electric motor.
4.6 Solenoid valve (US 5469886 A)
In a solenoid valve comprising a first solenoid valve for regulating pressure and a second
multifunctional solenoid valve integrated with the first solenoid valve, even if a solenoid
of the first solenoid valve is energized, a diaphragm valve of the solenoid
immediately opened, thereby providing a safe &
solenoid valve comprises a first spring provided between the upper end of a plunger
which is movable by the solenoid and stator, while the lower end of the plung
disposed to be brought into contact with the diaphragm valve and a second spring is
provided for urging the diaphragm valve in the direction to close it even if the plunger is
moved away from the diaphragm valve and the second solenoid valve
said solenoid valve for controlling to selectively open/
valve.
Figures 3.13 Solenoid Valve
US 5469886 A)
a solenoid valve comprising a first solenoid valve for regulating pressure and a second
multifunctional solenoid valve integrated with the first solenoid valve, even if a solenoid
of the first solenoid valve is energized, a diaphragm valve of the solenoid valve is not
ed, thereby providing a safe & compact solenoid valve. The first
solenoid valve comprises a first spring provided between the upper end of a plunger
which is movable by the solenoid and stator, while the lower end of the plung
disposed to be brought into contact with the diaphragm valve and a second spring is
provided for urging the diaphragm valve in the direction to close it even if the plunger is
moved away from the diaphragm valve and the second solenoid valve, integra
ntrolling to selectively open/close a closing valve and a one way
Solenoid Valve
35
a solenoid valve comprising a first solenoid valve for regulating pressure and a second
multifunctional solenoid valve integrated with the first solenoid valve, even if a solenoid
valve is not
compact solenoid valve. The first
solenoid valve comprises a first spring provided between the upper end of a plunger
which is movable by the solenoid and stator, while the lower end of the plunger is
disposed to be brought into contact with the diaphragm valve and a second spring is
provided for urging the diaphragm valve in the direction to close it even if the plunger is
integrated with
close a closing valve and a one way
36
Problems with Prior art
(a) Since the plunger is directly connected to the diaphragm valve, the diaphragm valve is
immediately opened when the solenoid is energized. Accordingly, when an atmosphere
opening passage of the canister which is open to the atmosphere is clogged or resistance
there through is large, the negative pressure in the intake manifold is introduced into the
second connecting passage, then passes through the diaphragm valve and the first
connecting passage, whereby the fuel tank is negatively pressurized to apply stress in the
fuel tank. As a result, there is a likelihood of breakage of the fuel tank.
(b) Since the stopper formed of the rubber or the nonmagnetic material is attached to the
stator by way of sticking of the stopper to the stator, if the stopper is detached from the
stator, the plunger is prevented from being slid. As a result, there is likelihood that the
solenoid valve is prevented from working normally.
(c) Since the pressure regulating solenoid valve and the atmosphere introduction valve are
separately provided, both valves need individual spaces for attachment thereof.
(d) Since the evaporated fuel generated in the fuel tank is condensed in the first and
second connecting passages and liquefied therein, there is a likelihood that the valve
performance is changed or the evaporated fuel leaks outside, which causes a fire.
Summary
The present invention has been made in view of the problems of the prior art solenoid
valve. It is an object of the present invention to provide the solenoid valve which is safe
and compact since a diaphragm valve is not immediately opened even if the pressure
regulating solenoid valve is energized.
It is another object of the invention to provide a solenoid valve comprising two solenoid
valves which are integrated with each other to thereby make the solenoid valve compact.
To achieve the above objects, the solenoid valve according to a first aspect of the
invention comprises a first connecting passage connected to a fuel tank side, a second
37
connecting passage connected to an intake manifold side, a diaphragm valve for
permitting both the first and second connecting passages to communicate with each other,
a solenoid body having a solenoid, a plunger and a stator wherein the plunger vertically
movable by the solenoid and the stator is disposed above the plunger, a first spring
disposed between the upper end of the plunger and the stator wherein the lower end of the
plunger is disposed to be able to contact with the diaphragm valve, and a second spring
disposed between the diaphragm valve and the solenoid body for urging the diaphragm
valve in the direction to close it in the state where the plunger is moved away from the
diaphragm valve.
A solenoid valve according to a second aspect of the invention is characterized in that
there are provided in the first aspect of the invention a hole or groove defined vertically in
the stator and a stopper formed by mold of the nonmagnetic material provided in the hole
or groove for stopping the plunger.
A solenoid valve according to a third aspect of the invention is characterized in that there
are provided in the first aspect of the invention a solenoid valve for adjusting pressure
between the first and second connecting passages, a bypass passage between the first and
second connecting passages, a one way directional valve (hereinafter referred to as one
way valve) between the bypass passage and a third connecting passage, a closing valve
between the bypass passage and the second connecting passage and a second solenoid
valve which is integrated with the first solenoid valve for controlling to selectively open
or close the closing valve and the one way valve.
A solenoid valve according to a fourth aspect of the invention in characterized in that the
third connecting passage serves as an atmosphere passage, the one way valve serves as an
atmosphere introduction valve, and the closing valve serves as a negative pressure
introduction valve.
A solenoid valve according to a fifth aspect of the invention is characterized in that there
is provided an evaporation device for evaporating liquefied material due to capillarity in
the second solenoid valve, the first connecting passage or the second connecting passage
in the third aspect of the invention
4.7 Direct solenoid operated directional control valve
A spherical valve member is m
direct application of supply pressure and operation of a solenoid arranged to maximize
mechanical force imposed on the valve member while minimizing solenoid size and
eliminating the use of movable close
sticking in the presence of solid contaminants.
Figure 3.14 Direct solenoid operated directional control valve
Direct solenoid operated directional control valve (US 4338966 A
A spherical valve member is moved within a housing between operative positions by
direct application of supply pressure and operation of a solenoid arranged to maximize
mechanical force imposed on the valve member while minimizing solenoid size and
eliminating the use of movable close fitting cylindrical parts which can be subject to
sticking in the presence of solid contaminants.
Direct solenoid operated directional control valve
38
US 4338966 A)
oved within a housing between operative positions by
direct application of supply pressure and operation of a solenoid arranged to maximize
mechanical force imposed on the valve member while minimizing solenoid size and
fitting cylindrical parts which can be subject to
Direct solenoid operated directional control valve
39
Description
Referring first to FIG. 1, the invention directional control valve is illustrated in one
preferred embodiment configured for installation in a fluid submerged environment such
as the valve housing of an automotive automatic transmission as including generally a
valve housing, a valve assembly carried in the valve housing, and an actuating solenoid
assembly carried with the housing and operatively engageable with the valve assembly.
The valve housing is illustrated as including a ported body to which is secured by screws
or the like a cover plate. An elongated valve chamber is formed in the body by a stepped
bore having a reduced diameter inner portion and an enlarged diameter outer portion. A
first passage communicates with the valve chamber portion and is connectable by means
well known in the hydraulic arts with a source of pressurized fluid such as a transmission
pump (not shown). A second passage communicates with the valve chamber portion and
is connectable by similar means with a fluid responsive device such as a fluid actuating
cylinder of an automotive automatic transmission (not shown).
Turning next to the valve assembly, it is illustrated as comprising a seat member, a
retainer member, a guide member, a ball, and an actuating plunger. The seat member is
preferably formed as a disc having a central bore and received in closely fitting diametral
relationship in the enlarged diameter chamber portion, abutting the terminal shoulder 31
thereof.
The retainer member includes a large diameter portion which is likewise received in
closely fitting diametral relationship in the enlarged diameter chamber portion 30 and
abuts the seat member to effect axial retention. The retainer member also includes a
reduced diameter neck portion extending outward (rightward as viewed in FIG. 1) from
the large diameter portion, and has formed through it a central stepped bore having an
enlarged diameter valve portion traversed perpendicularly by a cross port and a reduced
diameter connecting portion. The inner terminus of portion and the outer terminus of seat
through bore together form a pair of spaced, axially aligned valve seats for a purpose to
be hereafter described.
The guide member is formed as a substantially cylindrical member having an elongated
solenoid mounting portion and an inner terminal radially extending flange portion. It
further includes a central through bore having an inner portion sized to receive the neck
40
portion of retainer member in close fitting diametral relationship, a smaller plunger access
portion, and a retaining shoulder there between. A cross port extends through the bore at a
position adjacent the outer terminus of the neck portion of retainer member.
The ball member is loosely carried within the enlarged diameter valve portion of the
retainer member and is movable to selectively engage the valve seats in a manner to be
hereafter described.
The plunger member is carried for axial movement within the guide member and is
formed as an elongated rod having an actuating stem portion, a guide portion, an
elongated rod portion, and a solenoid connecting portion.
The stem portion is preferably cylindrical and passes along the axis of the connecting
portion of retainer stepped bore to abuttingly engage the ball. Its outer terminus
preferably includes a blend radius to the larger diameter of the guide portion.
Guide portion is preferably, but not necessarily formed as a generally cylindrical fluted
structure (as may best be seen in FIG. 4) defining an outer diameter slidingly received in
loose fitting relationship with the bore of guide member for movement between the
shoulder and the outer terminus of the retainer member. The mentioned fluted
construction is preferred, since it minimizes the surface areas in sliding contact, thus
reducing the tendency to stick; but in the FIG. 1 embodiment the critical functional
limitation on the structure of the guide portion is that it permit communication between
the connecting bore portion of retainer member 38 and at least the cross port of guide
member when the guide portion abuts the outer terminus of the retainer member.
Rod portion is preferably cylindrical and extends outwardly from the guide portion 76 to
the solenoid connecting portion.
Solenoid connecting portion includes inner enlarged diameter portion and outer retainer
receiving groove. Inner portion includes an outward facing chamfer connecting its outer
diameter with connecting portion.
41
Turning next to the solenoid assembly, it is illustrated as a clapper type solenoid
including essentially a mounting bracket, a solenoid core assembly, and a clapper type
armature.
The mounting bracket is preferably formed as a generally L-shaped member having a
vertical (as shown in FIG. 1) leg configured to be conventionally secured as by threaded
fasteners, as seen in FIG. 3, to the valve body. The inner surface of the leg may include a
recess for receiving the flange portion of guide member, thereby effecting axial retention
of the valve assembly. It may also include an aperture for conventionally receiving and
retaining the core assembly. Extending outward from the vertical leg is a generally
horizontal leg, preferably including a portion turned vertically to support the armature
providing a large flux area therewith. Notches are formed in the sides of the leg, and the
formation of the portion leaves support posts as may best be seen in FIG. 3.
The armature is secured to the mounting bracket for pivotal movement thereabout by
means of a special retaining member formed as by stamping from a resilient material such
as spring steel and including a strap portion and a leaf spring portion. Strap portion
includes apertures. The former engage notches in snap fit relationship, and the latter
loosely receive the posts to prevent rotation about the longitudinal axis of the horizontal
leg.
The end of the armature remote from its point of pivotal support on the vertical portion is
reduced in section as shown in FIG. 3 and includes a through aperture sized to pass the
connecting portion of the plunger. A preferably chamfered surface is formed at the inner
terminus of the aperture to cooperatively abuttingly engage the chamfered surface of the
plunger to permit self-centering of the plunger thereby resisting binding. It will be
appreciated by those skilled in the art that other cooperating surface configurations such
as matching spherical surfaces might be chosen for this purpose.
As may best be seen in FIG. 3, leaf spring portion is slotted at its free end as indicated at
to receive connecting portion of plunger. A conventional retaining ring received in the
groove of the plunger secures the assembly axially. The leaf spring portion is formed at
assembly to exert a small preload on the plunger in the rightward direction as viewed in
FIG. 1. Armature is also formed by bending at assembly to provide a predetermined
spacing from the core assembly.
42
Summary
Responsive to the deficiencies in the prior art, it is an object of the present invention to
provide a directly solenoid operated directional control valve that is resistant to sticking.
It is another object to provide such a valve which maximizes the actuation force and
travel produced by the solenoid.
It is yet another object to provide such a valve which minimizes contact stresses in
actuation.
It is still another object to provide such a valve which is simple and economical to
produce.
According to one feature of the present invention, a solenoid operated directional control
valve is provided which employs a minimal number of close fitting moving cylindrical
parts.
According to another feature, the solenoid of the valve of the present invention is coupled
to an actuating plunger for the valve portion with mechanical advantage and is arranged
such that operation against large preload forces is not required.
According to yet another feature, contact between the valve operative structure and the
actuating plunger therefore is maintained in the unactuated condition of operation to
substantially prevent impact loading.
43
Research Paper
THE CAVITATION IN ZONE BODY-SPOOL VALVE
FOR HYDRAULIC DISTRIBUTOR
Abstract.
The cavitation phenomena which occurring in hydraulic machinery and hydraulic
equipment, is for many years a research topic, which lead to great running improvements
of the hydraulic systems. Cavitation occurs in some elements of hydraulic drive devices
as a result of great increases of the flow velocity. In distributors it represents the major
limits the possibility to reduce the flow capacity beyond some values. The initiation and
the development of the cavitation in hydraulic drive systems present some particularities
originated both in the liquid employed (especially mineral oil) and the severe running
conditions. The cavitation erosion is generally not a very stressing factor. On the other
hand, as a result of important modifications in the characteristics of the working fluid,
when the pressure decreases (increasing of the gas and steam content) the running of the
system is heavily disturbed.
Having as a start point in general the definition of cavitation coefficients for the
directional valves with cylindrical spools. For this definition, there were taken into
account all the important aspects of the flow geometry and the elements depending on the
fluid nature. By attentive examinations of the flow through the specific hydraulic
resistance it was established a relation to obtain the cavitation reserve of the system.
1. The cavitation phenomenon in distribution section distributor body - spool valve
The hydraulic resistance describes hydraulic system elements with diverse
functional role, and the diversity of type construction assures the purpose for their role.
The majority of hydraulic resistance works by strangle the flow vein . From this reason
the cavitation phenomena can occurs during with increasing speed and the different
pressure values in different points of the hydraulic resistance. In hydraulic distribution
apparatus, the cavitation phenomenon occurs in case of command resistance with small
aperture, where the speed will be increased, and from Bernoulli equation results that the
pressure drops in the case when exists a big drop of pressure on the command resistance.
The distributor hydraulic track is characterized by the distributor body-spool valve
geometry, and different type of spool valves geometry. For studying the cavitation regime
in hydraulic resistance distributor body-spool valve , the research had focus to determine
energetic spectrum of analyse cavitation effect among the hydraulic distribution apparatus
44
45
CHAPTER 4
Design Phase
3.1 Introduction
The preliminary design for the current to pressure converter includes design of following
entities:
Orifice size
Cylinder diameter
Spool diameter
Seal selection
Gland diameter
Gland thickness
The preliminary design for the current to pressure converter includes design of following
46
The preliminary design for the current to pressure converter includes design of following
47
Fig 4.1 Introduction to CPC
3.2 Design of orifice
The flow coefficient of a device is a relative measure of its efficiency at
allowing fluid flow. It describes the relationship between the pressure drop across
an orifice, valve or other assembly and the corresponding flow rate.
Mathematically the flow coefficient can be expressed as:
C
V
=
??
?
Where
C
v
= Flow coefficient or flow capacity rating of valve.
F = Rate of flow (US gallons per minute).
SG = Specific gravity of fluid (Water = 1).
P = Pressure drop across valve (psi).
Following the above equation,
for port A, C
V
=1.5793
for port T, C
V
=1.9724
Input Parameters:
Specific Gravity of Hydraulic Oil used = 0.9
For PA
Q = 24 Lpm at 1 bar pressure difference
For AT
Q = 30 Lpm at 1 bar pressure difference
*Lpm= Liter per minute of oil
1 LPM= 0.264172052 GPM (US)
1 Bar= 14.503 Psi
48
For finding orifice diameter, we have used the Spirax Sarco Calculator. It gives the
experimentally determined value for orifice diameter corresponding for that value of the
flow coefficient. This is taken as a reference.
Fig 4.2 Spirax Sarco Calculator
For ports A and B, the values of diameters are,
d
A
= 6.37 mm
d
B
= 7.12 mm
3.3 Bore Diameter
Bore is the inner cylindrical portion of the valve which encloses the spool. The annular
area between the bore and spool should be equal to the orifice area.
We select the largest of the area of A and T.
49
Area of A orifice = r
2
= (7.12/2)
2
= 39.79511
This area should be maintained inside cylinder including 5mm of spool.
So,
( R
2
-r
2
)= 39.79 mm
Here r = 0.25mm spool radii
D= 2R= 8.7 mm
3.4 Oil Seal Selection
There are lots of physical conditions which need consideration before an engineer opts to
use seal or seal material for the specific application
The governing factors are:
1. Working Pressure and pressure range
2. Environmental condition
3. Fluid medium
4. Static or dynamic application
5. Temperature of the system
6. Functional reliability and expected life
But in order to generate a failsafe sealing system, the above factors may not be enough.
One has also to look for the physical and chemical properties of the seal materials used. A
through look at the following material properties, especially in case of elastomeric seals is
therefore very essential for the designers as well as for the maintenance engineers in order
to make an optimum choice.
Some of these properties are:
a. Hardness
b. Friction
c. Volume change
50
d. Compression set
e. Tensile strength
f. Elongation probability of change
g. Tear strength and abrasion resistance
h. Thermal effects and heat resistance
i. Squeeze and anti extrusion property
j. Stretch or tensile strength
k. Coefficient of thermal expansion
l. Permeability
m. Oil compatibility
n. Ageing
o. Corrosion resistance
p. Ozone and weather resistance
q. Electrical properties
The following calculations are made from the Parker manual for O-Rings, being widely
used for seal selection.
O-rings can be molded in a wide range of compounds in hardness from 40 to 95 Shore A.
These materials include:
Acrylonitrile-Butadiene (NBR)
Butyl (IIR)
Chloroprene (CR)
Ethylene Acrylic (AEM)
Ethylene Propylene (EPDM)
Fluorocarbon (FKM)
Fluorosilicone (FVMQ)
Hydrogenated Nitrile (HNBR)
Perfluoroelastomer (FFKM)
Polyacrylate (ACM)
Silicone (VMQ)
51
Table 4.1 Temperature Range for common elastomers
(P.T.O)
52
Fig 4.3 Compressibility Chart
Table 4.2 Comparison of commonly used elastomers
53
We select Polyurethane due to following reasons
(a)It has high abrasion resistance, low friction
(b)Suitable for high pressure, shock load
(c)Temperature range of -50 to 150 degree Celsius
(d)Shore hardness of 95-105A
According to the sizing charts, following range of products are available:
2-0XX (C/S=1.78 0.08)
2-1XX (C/S=2.62 0.08)
2-2XX (C/S=3.53 0.10)
2-3XX (C/S=5.33 0.13)
2-4XX (C/S=6.99 0.15)
Since the bore diameter is required to be 8.7, we may select the O-ring from 2-0XX
series.
(P.T.O)
54
Fig 4.4 2-0XX selection chart
55
Considering the bore diameter to be 8.70.05, and cross section diameter to be 1.78, we
get the inner diameter to be 5.35 or 4.93. Now, if the limits are such that bore is of 8.65
and the c/s is 1.86, then ID of 5.35 would further compress the ring, providing better
leakage resistance. While the other case would result in loose ring, which would cause
leakage. Thus, we select a ring which has ID closer to 5.35.
So, we select the ring 2-009.
According to it, the inside diameter of the ring is 5.280.13
But in the case where,
Bore=8.75,
ID=5.15,
C/S=1.70,
ID+2(C/S)=8.55<Bore
So, there is a possibility of loose fitting.
So, we select 2-010 ring, having following dimensions:
Inner Diameter: 6.070.13
Cross Section: 1.780.08
56
CHAPTER 5
Conclusion and Future Scopes
57
Conclusion:
During our work course and study, we have gained the understanding of the governing
principles for the CPC, thereby analyzing different possible mechanisms for its optimum
functioning.
Following the design procedure, facilitating failure safe functioning of the product, we
have reached till the selection of O-rings for static and dynamic operations of the CPC.
Also, in the coming months, we plan to complete the designing procedure thoroughly and
continue to the next step, i.e. analysis of the proposed design.
Future plans
Gland Design
Valve orifice configuration
Spool design (detail engineering)
Force Calculations
Electronic controller of CPC
58
References:
1. Spirax Sarco website (www.spiraxsarco.com)
2. APPLIED INSTRUMENTATION IN PROCESS INDUSTRIES Vol1a by
W.G. Andrew,
3. Siemens website (www.siemens.com)
4. Parker O-Ring handbook
5. Hydraulics by S.R. Majumdar