Features of HydraForce Cartridge Valves

Analysis of Technical Features of Lianlai Hydraulic Haidafos Cartridge Valve

I. Overview of Cartridge Valve Technology

Cartridge valves, as core control components in modern hydraulic systems, have been widely applied in the industrial field due to their modular design, high integration and excellent performance. This type of valve adopts an insertable installation structure and can be quickly assembled and replaced through a standard cavity, significantly enhancing the flexibility and maintenance efficiency of the hydraulic system. Among the numerous cartridge valve products, the HYDRAFORCE series represents the leading level in the industry, and its technical features are worth in-depth exploration.

Ii. Structural Design and Manufacturing Process Characteristics

Compact modular design: This series of cartridge valves adopts a highly integrated structural design, achieving multi-functional integration within a limited space. The valve body is made by precision casting process, and the internal flow channel is optimized by CFD design, which significantly reduces pressure loss and improves energy utilization rate. The typical product's external dimensions are reduced by more than 30% compared to traditional valves, and its weight is decreased by approximately 25%. It is particularly suitable for hydraulic system applications with limited space.

2. Precision processing technology: Key components are processed by CNC machine tools, with the processing accuracy of mating surfaces reaching Ra0.2μm, ensuring the sealing performance of the valve under high-pressure conditions. The fit clearance between the valve core and the valve sleeve is controlled within the range of 3 to 5μm, which not only ensures the flexibility of movement but also effectively controls internal leakage.

3. Material selection and treatment: The main material is high-strength alloy steel, which undergoes a special heat treatment process. The surface hardness reaches above HRC60, and it has excellent wear resistance. The sealing parts are made of special fluororubber or polyurethane materials, which have outstanding oil resistance and high-temperature resistance, maintaining stable performance within the temperature range of -40℃ to 120℃.

Iii. Performance Parameters and Technical Advantages

1. High-pressure and high-flow characteristics: The rated working pressure of this series of cartridge valves can reach 420bar, and the instantaneous pressure resistance capacity exceeds 630bar. The flow range is extensive, with different specifications available from a few liters per minute to over a thousand liters. The pressure loss is controlled within 0.3MPa (at the rated flow), significantly enhancing the system's energy efficiency.

2. Fast response feature: With an optimally designed pilot control structure, the reversing time can be controlled within 10 to 30 milliseconds, making it particularly suitable for hydraulic systems that require high-frequency response. Dynamic tests show that it can still maintain stable control performance at a working frequency of 100Hz.

3. Low leakage design: Through precisely processed cone valve structure, the internal leakage is less than 5 drops per minute when closed (at rated pressure), far exceeding the requirements of ISO standards. This characteristic makes it particularly suitable for working conditions that require long-term pressure holding.

4. Multi-functional integration: A single valve body can integrate multiple functions such as directional control, pressure regulation, and flow control. Through different pilot control methods, complex logic control functions can be achieved, greatly simplifying the design of the hydraulic system.

Iv. Special Functions and Innovative Technologies

1. Intelligent control compatibility: The design of the new generation of products takes into account compatibility with electronic control systems and can be directly connected to proportional electromagnets or servo motors to achieve precise electronic control. Some models are equipped with built-in LVDT position feedback, providing a hardware foundation for closed-loop control.

2. Anti-pollution design: By adopting a large cavity filtration structure and a specially designed valve core geometry, the tolerance to oil contamination is significantly enhanced. Tests show that it can still work reliably in the oil with a NAS contamination level of 9, reducing the system maintenance requirements.

3. Application of energy-saving technologies: Some models adopt pressure compensation and load sensitivity designs, which can automatically adjust flow and pressure according to actual needs, achieving energy-saving effects of 20% to 40%. The specially designed low-power pilot control structure minimizes the energy loss of the entire system.

4. Environmental Adaptability: Through special surface treatment and material selection, the product has excellent corrosion resistance and can adapt to harsh environments such as at sea and in mines. The explosion-proof design model has passed the ATEX certification and can be used in explosion-proof requirements.

V. Application Fields and Selection Suggestions

This type of high-performance cartridge valve is widely used in:

- Construction machinery: Hydraulic control systems for excavators and loaders

- Metallurgical equipment: Hydraulic drive systems for continuous casting machines and rolling mills

- Marine machinery: Hydraulic systems for steering gears and deck machinery

- Energy equipment: Wind power pitch systems, oil drilling and production equipment

When making a selection, key considerations should be given to:

1. System working pressure and flow requirements

2. Control mode (manual, electromagnetic, proportional, etc.

3. Environmental conditions (temperature, humidity, explosion-proof requirements, etc.)

4. Special functional requirements (such as pressure compensation, load sensitivity, etc.

Vi. Maintenance and Fault Handling

Proper maintenance can significantly extend the service life

Regularly check the condition of the filter to maintain the cleanliness of the oil

Check the condition of the seals every 2,000 hours of operation

When the machine is out of service for a long time, the valve should be in the unloaded state

Common Fault Handling

1. Slow response: Check if the pilot pressure is normal and clean the valve core

2. Internal leakage: Check if the sealing surface is worn and replace the valve core assembly if necessary

3. Abnormal noise: Check the contamination level of the oil and rule out the possibility of cavitation

Vii. Technological Development Trends

The future cartridge valve technology will develop in the following directions:

A higher degree of intelligence, integrating sensors and iot interfaces

2. Applications of new materials, such as ceramic valve cores and nano-coating technology

3. More environmentally friendly design, reducing noise and energy consumption

4. The integration of digital hydraulic technology enables direct digital control

This high-performance cartridge valve, through continuous technological innovation, constantly drives the advancement of hydraulic control technology and provides reliable and efficient power control solutions for various industrial equipment. Its outstanding technical characteristics and wide application adaptability make it an indispensable key component in the design of modern hydraulic systems.